Sie sind auf Seite 1von 140

Power Products

Reference Manual
UTILUX
Utilux is a brand that has built an enviable reputation for high quality, reliable electrical connectors. For over 80 years,
this dynamic Australian brand has been a leader in the field of interconnection systems. Utilux has now joined the
truly innovative, international market leader, Tyco Electronics.

Our aim is to provide the best possible products and services to keep our customers at the cutting edge of industry
standards - internationally.

QUALITY YOU CAN RELY ON


The Utilux manufacturing operation is certified to International Standards Organisation (ISO) 9001:2000 quality
standards, the benchmark for the worlds best practice in design and production facilities and methods. Tyco’s highly
skilled technical team ensures that these optimal standards are inherent in every product that leaves our factories.
You can be sure that Utilux branded products are fabricated from the finest materials and produced to exacting
tolerances. They represent the latest technology and the best design for the tasks they are required to perform.

RELIABLE ELECTRICAL CONNECTORS


Utilux is a leading brand of electrical connectors sold to original equipment manufacturers and electrical distribution
companies throughout Australia, New Zealand and Asia. A comprehensive range, the most up to date production
technology and the highest quality control standards ensure that there are Utilux connectors, of optimum reliability
and durability, for all major power distribution applications.

TESTING FACILITY
Located within Tyco Electronics Energy Division’s Wyong manufacturing facility is the largest NATA accredited test
facility owned and operated by a manufacturing supplier within the Australian and New Zealand market place.
Full test facilities are available, whether electrical, mechanical or environmental.

RESEARCH & DEVELOPMENT


As part of the worlds largest electrical connector company, the development of products is an ongoing commitment.
It is done on a global basis, utilising the talents of many people throughout the organisation to ensure a global
product for a local market.

TECHNICAL ASSISTANCE
Whether dealing direct with Tyco Electronics Energy Division or a Distributor, a full team of experienced technical
sales and support people are available to assist in the purchase of products shown in the catalogue or to
develop a solution to meet your particular needs.

CATALOGUE
This catalogue is correct at the time of printing but due to ongoing design reviews and product development,
Tyco Electronics Energy Division reserves the right to modify the specification of any product without notice.

ii FEB 2003
CONTENTS

COPPER CONDUCTOR TERMINATIONS SECTION 1

SECTION 1 COPPER CONDUCTOR TERMINATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1


COPPER CRIMP LUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CIRCUIT BREAKER LUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COPPER FLARED LUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
COPPER CRIMP LINKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
COPPER CRIMP LINKS – WITH SOLID BARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REDUCING LINKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
COPPER STALK LUG – TYPE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
COPPER STALK LUG – TYPE 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CRIMP CABLE CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CABLE LUG SOLDER TYPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SEALED COPPER CRIMP LUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
BOLTED CABLE LUG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
BOLTED TEE CLAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CAST LUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
‘C’ CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SOLID PALM COPPER LUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

CATALOGUE INDEX INDEX


COPPER CONDUCTOR TERMINATIONS

COPPER CRIMP LUG


• Suitable for copper conductor • Range 0.5-1000 mm2
• Seamless copper tube • Electro tinned
• Cable area clearly identified on the lug
• Tested to AS/NZS 4325.1:1995

CONDUCTOR CONDUCTOR STUD DIMENSIONS (mm2) NO. OF CRIMPS (Tool No.) CRIMPING
DESCRIPT. CAT NO.
AREA (mm2) STRANDING SIZE A B C D F G 76 00 18 20 21 22 38A DIE
CG0.5M4 H1399 M4 17.5 6.4 1.4 9.5 6.0 2.1 - - - - - - - -
CG0.5M4 H1400 M4 19.1 6.4 1.4 11.1 6.0 2.1 1 1 1 - - - - -
CG0.5SM5 H1401S M5 19.1 8.7 1.0 11.1 6.0 2.1 1 1 1 - - - - -
0.5 1/0.80
CG0.5LM5 H1401L M5 26.6 8.7 1.0 15.1 9.5 2.1 2 2 1 - - - - -
CG0.5M6 H1402 M6 26.2 10.3 0.9 15.1 9.5 2.1 2 2 1 - - - - -
CG0.5M8 H1402A M8 26.2 11.1 0.8 15.1 9.5 2.1 2 2 1 - - - - -
CG2.5M4 H1436A M4 21.4 9.1 1.1 11.9 8.0 2.5 2 1 1 - - - - -
CG2.5M5 H1436 M5 21.4 9.1 1.1 11.9 8.0 2.5 2 1 1 - - - - -
2.5 7/0.67
CG2.5M6 H1437 M6 26.2 10.3 0.9 15.1 8.7 2.5 2 2 1 - - - - -
CG2.5M8 H1437A M8 26.2 10.3 0.9 15.1 8.7 2.5 2 2 1 - - - - -
CG4SM5 H1403S M5 21.0 8.7 1.5 11.1 8.0 3.3 2 1 1 - - - - -
CG4LM5 H1403L M5 27.3 8.7 1.5 14.7 9.2 3.3 2 2 1 - - - - -
CG4M6 H1404 4 7/0.85 M6 27.8 10.3 1.2 15.1 9.5 3.3 2 2 1 - - - - -
CG4M8 H1404A M8 28.6 13.0 1.0 13.3 9.5 3.3 2 2 1 - - - - -
CG4M10 H1404B M10 28.6 13.0 1.0 16.3 9.5 3.3 2 2 1 - - - - -
CG6M6 H1405 M6 27.0 10.3 1.2 15.0 9.5 3.7 - 2 1 - 1 1 1
CG6M8 H1405A 6 7/1.04 M8 28.6 13.9 0.9 16.7 9.5 3.7 - 2 1 - 1 1 1 38-44CU
CG6M10 H1405B M10 28.6 13.9 0.9 16.7 9.5 3.7 - 2 1 - 1 1 1
CG10SM6 H1406S M6 27.0 11.9 1.8 15.5 9.5 4.7 - 2 1 - 1 1 1
CG10LM6 H1406L M6 29.4 11.9 1.8 15.5 11.5 4.7 - 2 2 - 1 1 1
CG10M8 H1406A 10 7/1.35 M8 28.6 14.3 1.6 16.3 9.5 4.7 - 2 1 - 1 1 1 38-57CU
CG10M10 H1406B M10 30.6 14.3 1.6 16.3 9.5 4.7 - 2 1 - 1 1 1
CG10M12 H1406C M12 33.0 17.0 1.4 20.0 11.0 4.7 - 2 1 - 1 1 1
CG16M5 H1407A M5 39.7 11.6 2.3 16.3 20.6 5.5 - - *3 2 2 2 1
CG16M6 H1407 M6 39.7 11.6 2.3 16.3 20.6 5.5 - - *3 2 2 2 1
38-63CU
CG16M8 H1408 M8 39.7 13.5 1.9 16.3 20.6 5.5 - - *3 2 2 2 1
16 7/1.70
CG16M10 H1408A M10 41.5 13.5 1.9 18.5 20.6 5.5 - - *3 2 2 2 1
CG16M11 H1445 M11 43.6 16.7 2.8 19.0 22.2 5.5 - - - 2 2 2 1 38-77CU
CG16M12 H1408B M12 46.0 17.5 1.4 20.5 19.0 5.5 - - - 2 2 2 1 38-63CU
CG20M6 H1409 M6 34.9 12.5 2.3 14.3 19.0 6.3 - - - 2 2 2 1
CG20M8 H1410 M8 42.1 13.5 2.2 19.0 20.3 6.3 - - - 2 2 2 1
20 19/0.44 38-70CU
CG20M10 H1411 M10 42.1 14.3 2.0 19.0 20.3 6.3 - - - 2 2 2 1
CG20M12 H1411A M11 42.1 15.2 1.9 19.0 20.3 6.3 - - - 2 2 2 1
CG25M6 H1415A M6 43.6 16.7 2.2 19.0 22.0 7.1 - - - 2 2 2 1
CG25M8 H1415 M8 43.6 16.7 2.2 19.0 22.0 7.1 - - - 2 2 2 1
CG25M10 H1416 25 19/1.35 M10 43.6 16.7 1.9 19.0 22.0 7.1 - - - 2 2 2 1 38-77CU
CG25M11 H1416A M11 43.6 16.7 1.9 19.0 22.0 7.1 - - - 2 2 2 1
CG25M12 H1416B M12 51.0 18.2 1.7 25.4 21.0 7.1 - - - 2 2 2 1

All sizes of crimp lugs are compatible with imperial size cables except those marked*

2
COPPER CONDUCTOR TERMINATIONS

CONDUCTOR CONDUCTOR STUD DIMENSIONS (mm2) NO. OF CRIMPS (Tool No.) CRIMPING
DESCRIPT. CAT NO.
AREA (mm2) STRANDING SIZE A B C D F G 20 21 22 38A 40B DIE
CG35M6 H1365 M6 43.6 18.2 2.7 19.0 22.2 8.4 2 2 2 1 -
CG35M8 H1366 M8 43.6 18.2 2.7 19.0 22.2 8.4 2 2 2 1 -
35 19/1.53 38-92CU
CG35M10 H1368 M10 43.6 18.2 2.7 19.0 22.2 8.4 2 2 2 1 -
CG35M12 H1369 M12 51.2 20.0 2.4 24.5 22.0 8.4 2 2 2 1 -
CG35M11 H1442 38 7/0.104 M11 51.6 19.0 3.7 27.0 22.2 8.7 2 2 2 1 - 38-104CU
CG50M8 H1419 M8 51.6 18.2 3.1 27.0 22.2 9.5 2 2 2 1 -
CG50M10 H1420 50 19/1.78 M10 51.6 19.0 3.0 27.0 22.2 9.5 2 2 2 1 - 38-104CU 1
CG50M12 H1421 M12 51.6 20.6 2.8 27.0 22.2 9.5 2 2 2 1 -
CG70M6 H1422B M6 54.0 20.6 3.2 27.0 23.0 11.0 2 - 2 1 -
CG70M8 H1422A M8 54.0 20.6 3.2 27.0 23.0 11.0 2 - 2 1 -
CG70M10 H1422 M10 54.0 20.6 3.2 27.0 23.0 11.0 2 - 2 1 - 38-115CU
70 19/2.14
CG70M12 H1423 M12 54.0 20.6 3.2 27.0 23.0 11.0 2 - 2 1 -
CG70M16 H1423A M16 54.2 27.5 2.4 27.0 22.0 11.0 2 - 2 1 -
CG70M11 H1443 M11 54.0 22.2 4.7 27.0 23.0 11.2 2 - 2 1 - 38-130CU
Is H1438 Sleeved
CG70M20 H1439 to suit 19/.083 M20 76.0 28.6 3.5 45.0 25.4 11.0 - - - 1 1 38-142CU
CG95M6 H1424B M6 57.2 25.4 4.0 27.0 27.0 13.4 2 - 2 1 1
CG95M8 H1424C M8 57.2 25.4 4.0 27.0 27.0 13.4 2 - 2 1 1
CG95M10 H1424 M10 57.2 25.4 4.0 27.0 27.0 13.4 2 - 2 1 1 38 -142CU
95 37/1.78
CG95M12 H1425 M12 57.2 25.4 4.0 27.0 27.0 13.4 2 - 2 1 1 40-142CU
CG95M16 H1440 M16 75.5 27.0 3.7 45.0 25.4 13.4 2 - 2 1 1
CG95M20 H1438 M20 75.5 28.6 3.5 45.0 25.4 13.4 2 - 2 1 1
CG120M10 H1381 M10 68.3 30.0 4.8 31.8 31.0 15.5 - - 2 1 1
CG120M12 H1382 M12 68.3 30.0 4.8 31.8 31.0 15.5 - - 2 1 1 38 -165CU
120 37/2.03
CG120M16 H1383 M16 68.3 30.0 4.8 31.8 31.0 15.5 - - 2 1 1 40-165CU
CG120M20 H1382B M20 68.3 30.0 4.8 31.8 31.0 15.5 - - 2 1 1
CG150M10 H1384A* M10 75.0 33.5 5.4 41.3 27.0 16.3 - - - 1 1
CG150M12 H1384* M12 75.0 33.5 5.4 41.3 27.0 16.3 - - - 1 1 38 -183CU
150 37/2.25
CG150M16 H1385* M16 75.0 33.5 5.4 41.3 27.0 16.3 - - - 1 1 40-185CU
CG150M20 H1386* M20 75.0 33.5 5.4 41.3 27.0 16.3 - - - 1 1
CG185M10 H1387A M10 79.0 36.5 5.2 41.3 31.0 18.4 - - - 1 1
CG185M12 H1387 M12 79.0 36.5 5.2 41.3 31.0 18.4 - - - 1 1 38 -200CU
185 37/2.52
CG185M16 H1388 M16 79.0 36.5 5.2 41.3 31.0 18.4 - - - 1 1 40-200CU
CG185M20 H1389 M20 79.0 36.5 5.2 41.3 31.0 18.4 - - - 1 1
CG240MB H1390* MB 127.0 41.6 7.1 54.0 47.6 21.2 - - - 3 1
CG240M10 H1390D* M10 127.0 41.6 7.1 54.0 47.6 21.2 - - - 3 1
38 -231CU
CG240M12 H1390A* 240 61/2.25 M12 127.0 41.6 7.1 54.0 47.6 21.2 - - - 3 1
40-231CU
CG240M16 H1390B* M16 127.0 41.6 7.1 54.0 47.6 21.2 - - - 3 1
CG240M20 H1390C* M20 127.0 41.6 7.1 54.0 47.6 21.2 - - - 3 1
CG300MB H1391 MB 127.0 46.0 7.9 54.0 47.6 23.8 - - - 3 1
38 -260CU
CG300M16 H1391A 300 61/2.52 M16 127.0 46.0 7.9 54.0 47.6 23.8 - - - 3 1
40-260CU
CG300M20 H1391B M20 127.0 46.0 7.9 54.0 47.6 23.8 - - - 3 1
CG400MB H1448 MB 123.0 49.6 7.9 54.0 41.3 26.9 - - - - 1
40-281CU
CG400M16 H1448A 400 61/2.85 M16 123.0 49.6 7.9 54.0 41.3 26.9 - - - - 1 50-281CU
CG400M20 H1448B M20 123.0 49.6 7.9 54.0 41.3 26.9 - - - - 1 66-281CU

CG500MB H1449 MB 142.5 54.8 8.2 54.0 55.5 30.0 - - - - 2


40-310CU
CG500M16 H1449A 500 61/3.20 M16 142.5 54.8 8.2 54.0 55.5 30.0 - - - - 2 50-310CU
CG500M20 H1449B M20 142.5 54.8 8.2 54.0 55.5 30.0 - - - - 2 66-310CU

40-370CU
CG630MB H1394* 630 127/2.52 MB 146.0 63.5 11.5 54.0 58.0 33.5 - - - - 2 50-370CU
CG800MB H1370 800 127/2.85 MB 275.0 75.0 14.0 127.0 105.0 39.3 - - - - 3 40-432CU
CG1000MB H1371 1000 127/3.20 MB 295.0 85.0 16.0 125.0 110.0 44.0 - - - - 3 40-480CU

3
COPPER CONDUCTOR TERMINATIONS

NARROW PALM
• Specially made for terminating large cables to circuit breakers
• Unique bell mouth for easy insertion
of fine stranded conductors
• Made for 99.9%+ high
conductivity copper

NOMINAL DIMENSIONS mm NO. OF CRIMPS (Tool NO.) CRIMPING


CAT NO. BOLT
CONDUCTOR A B C D F G 20 21 22 38A 40B DIE
SIZE
mm 2

CGNP35M6 35 M6 44 15 2.7 15 21 8.4 2 2 2 1 - 38-92CU


CGNP50M6 50 M6 52 15 3.0 15 22 9.5 2 2 2 1 -
38-104CU
CGNP50M10 50 M10 52 19 3.0 21 22 9.5 2 2 2 1 -
CGNP70M6 70 M6 54 17 3.2 15 24 11.0 2 - 2 1 -
38-115CU
CGNP70M10 70 M10 54 19 3.2 21 24 11.0 2 - 2 1 -
CGNP95M8 95 M8 57 19 4 17 27 13.4 2 - 2 1 -
38-142CU
CGNP95M10 95 M10 57 19 4 21 27 13.4 2 - 2 1 -
CGNP120M8 120 M8 68 19 4.8 23 30 15.5 - - 2 1 1
38-165CU
CGNP120M10 120 M10 68 19 4.8 23 30 15.5 - - 2 1 1
CGNP150M8 150 M8 75 19 5.4 27 30 16.3 - - - 1 1
38-183CU
CGNP150M10 150 M10 75 19 5.4 27 30 16.3 - - - 1 1
CGNP185M10 185 M10 79 31 5.2 32 32 18.4 - - - 1 1 38-200CU
CGNP240M10 240 M10 127 31 7.1 32 38 21.2 - - - 3 1
38-231CU
CGNP240M12 240 M12 127 31 7.1 32 38 21.2 - - - 3 1
CGNP300M10 300 M10 127 31 7.9 32 42 23.8 - - - 3 1
38-260CU
CGNP300M12 300 M12 127 31 7.9 32 42 23.8 - - - 3 1

4
COPPER CONDUCTOR TERMINATIONS

COPPER FLARED LUGS


The range of flared copper lugs has been designed with the barrel entry flared to enable an easy insertion of multi
stranded cables (flexible cable). The range of connectors (from 25mm2 to 185mm2) will ensure most applications for
the common flexible cable sizes are covered. The flared copper lugs are made from seamless copper tube, electro tin
plated and have the cable area clearly marked on the palm of the lug. The inspection window on the barrel provides
a check that the cable has been fully inserted. The flared lugs can be crimped with the standard range of Utilux
tooling and hexagonal dies.

CONDUCTOR STRANDING BOLT DIMENSIONS (mm) NO. OF CRIMPS (Tool No.) CRIMPING
CAT NO.
SIZE (mm2) METRIC SIZE A B D F 20 21 22 38A 40B DIE
CG25FLM6 209/0.40 M6 44 17 19 22 2 2 2 1 -
CG25FLM8 209/0.40 M8 44 17 19 22 2 2 2 1 -
25 38-77CU
CG25FLM10 209/0.40 M10 44 17 19 22 2 2 2 1 -
CG25FLM12 209/0.40 M12 44 17 19 22 2 2 2 1 -
CG35FLM6 285/0.40 M6 44 18 19 22 2 2 2 1 -
CG35FLM8 285/0.40 M8 44 18 19 22 2 2 2 1 -
35 38-92CU
CG35FLM10 285/0.40 M10 44 18 19 22 2 2 2 1 -
CG35FLM12 285/0.40 M12 44 18 19 22 2 2 2 1 -
CG50FLM8 380/0.40 M8 52 21 27 22 2 2 2 1 -
CG50FLM10 50 380/0.40 M10 52 21 27 22 2 2 2 1 - 38-104CU
CG50FLM12 380/0.40 M12 52 21 27 22 2 2 2 1 -
CG70FLM6 203/0.67 M6 54 21 27 23 2 - 2 1 -
CG70FLM8 203/0.67 M8 54 21 27 23 2 - 2 1 -
70 38-115CU
CG70FLM10 203/0.67 M10 54 21 27 23 2 - 2 1 -
CG70FLM12 203/0.67 M12 54 21 27 23 2 - 2 1 -
CG95FLM6 259/0.67 M6 57 25 27 27 2 - 2 1 -
CG95FLM8 259/0.67 M8 57 25 27 27 2 - 2 1 -
95 38-142CU
CG95FLM10 259/0.67 M10 57 25 27 27 2 - 2 1 -
CG95FLM12 259/0.67 M12 57 25 27 27 2 - 2 1 -
CG120FLM10 336/0.67 M10 68 30 32 31 - - 2 1 1
CG120FLM12 120 336/0.67 M12 68 30 32 31 - - 2 1 1 38-165CU
CG120FLM16 336/0.67 M16 68 30 32 31 - - 2 1 1
CG150FLM12 427/0.67 M12 75 34 32 27 - - - 1 1
150 38-183CU
CG150FLM16 427/0.67 M16 75 34 32 27 - - - 1 1
CG185FLM12 518/0.67 M12 79 34 32 31 - - - 1 1
185 38-200CU
CG185FLM16 518/0.67 M16 79 34 32 31 - - - 1 1

5
COPPER CONDUCTOR TERMINATIONS

COPPER CRIMP LINKS


• Solid drawn copper tube
• Centre dimples • Ends reamed

CONDUCTOR DIMENSIONS
STRANDING NO. OF CRIMPS (TOOL NO.) CRIMPING
DESCRIPT. CAT NO. AREA mm
METRIC 00 18 20 21 22 38A 40B DIE
mm2 A I.D.
CK0.5 H1451 0.5 1/0.80 22 2.1 2 - - - - - -
CK02.5 H1467 2.5 7/0.67 22 2.5 2 - - - - - -
CK4 H1452 4 7/0.85 22 3.3 2 1 - - - - -
CK6 H1453 6 7/1.04 22 3.7 2 1 - 2 2 1 - 38-44CU
CK10 H1454 10 7/1.35 22 4.7 2 1 - 2 2 1 - 38-57CU
CK16 H1455 16 7/1.70 44 5.5 - 3 2 2 2 1 - 38-63CU
CK20 H1456 20 19/.044 44 6.3 - - 2 2 2 1 - 38-70CU
CK25 H1458 25 19/1.35 48 7.1 - - 2 2 2 1 - 38-77CU
CK35 H1488 35 19/1.53 48 8.4 - - 2 2 2 1 - 38-92CU
CK50 H1460 50 19/1.78 48 9.5 - - 2 2 2 1 - 38-104CU
CK70 H1461 70 19/2.14 51 11.0 - - 2 - 2 1 - 38-115CU
CK95 H1462 95 37/1.78 54 13.4 - - 2 - 2 1 1 38-142CU
CK120 H1492 120 37/2.03 65 15.5 - - - - 2 1 1 38-165CU
CK150 H1493* 150 37/2.25 65 16.3 - - - - - 2 1 38-183CU
CK185 H1494 185 37/2.52 65 18.4 - - - - - 2 1 38-200CU
CK240 H1495 240 61/2.25 89 21.2 - - - - - 3 1 38-231CU
CK300 H1496 300 61.2.52 89 23.8 - - - - - 3 1 38-260CU
CK400 H1470 400 61/2.85 89 26.8 - - - - - - 1 40-281CU
CK500 H1471 500 61/3.20 114 30.0 - - - - - - 1 40-310CU
CK630 H1499* 630 127/2.52 114 33.5 - - - - - - 2 40-370CU
CK800 H1474 800 127/2.85 230 39.3 - - - - - - 3 40-432CU
CK1000 H1475 1000 127/3.20 230 43.8 - - - - - - 3 40-480CU

All sizes of crimp links are compatible with imperial size cables except those marked*

ver you nee


e
d
t
wha

P
L

C
AN HE

6
COPPER CONDUCTOR TERMINATIONS

COPPER CRIMP LINKS –


WITH SOLID BARRIER
• For use with oil filled cables
• Solid drawn copper rod • Electro tinned
• Solid centre barriers • Ends reamed

DESCRIPT. CAT NO.


CONDUCTOR STRANDING DIMENSIONS NO. OF CRIMPS (Tool No.) CRIMPING 1
AREA mm2 METRIC A I.D. 20 21 22 38A 40B DIE
CKB10 H1782 10 7/1.35 48 4.7 - 2 2 1 - 38-57CU
CKB16 H1781 16 7/1.70 44 5.5 2 2 2 1 - 38-63CU
CKB20 H1786 20 7/2.14 44 6.7 2 2 2 1 - 38-74CU
CKB25 H1779 25 19/1.35 48 7.1 2 2 2 1 - 38-77CU
CKB35 H1791 35 19/1.53 48 8.4 2 2 2 1 - 38-92CU
CKB50 H1770 50 19/1.78 54 9.5 2 2 2 1 - 38-104CU
CKB70 H1771 70 19/2.14 51 11.0 2 - 2 1 - 38-115CU
CKB95 H1772 95 37/1.78 54 13.4 2 - 2 1 1 38-142CU
CKB120 H1792 120 37/2.03 65 15.5 - - 2 1 1 38-165CU
CKB150 H1793 150 37/2.25 65 16.3 - - - 2 1 38-183CU
CKB185 H1794 185 37/2.52 65 18.4 - - - 2 1 38-200CU
CKB240 H1795 240 61/2.25 76 21.2 - - - 3 1 38-231CU
CKB300 H1796 300 61/2.52 76 23.8 - - - 3 1 38-260CU
CKB400 H1797 400 61/2.85 89 26.8 - - - - 1 40-281CU
CKB500 H1798 500 61/3.20 114 30.0 - - - - 1 40-310CU
CKB630 H1799 630 127/2.52 145 33.5 - - - - 2 40-370CU

CRIMP CABLE CONNECTOR


• Seamless drawn Copper tube
• Electro tinned

DIMENSIONS mm
CAT NO. SIZE STYLE TOOL NO.
A
H2038 1 7.9 1 00, 16B, 76B
H2033 1 15.1 2 00, 16B, 76B
H2039 2 7.9 1 00, 16B, 76B, 18A
H2034 2 15.1 2 00, 16B, 76B, 18A
H2035 3 14.3 2 00, 16B, 76B, 18A
H2042 2 x 24/0.20 6.4 1 00, 16B, 76B
H2022 2 x 50/0.25 8.5 1 00, 16B, 18A
H2027 3 x 32/0.20 9.5 1 00, 16B, 18, 76B
H2043 3 x 32/0.20 7.9 1 00, 16B, 18, 76B
H2029 5 x 32/0.20 9.5 1 00, 16B, 18A
H2041 2 x 50/0.25 11.1 1 20, 38A, 21, 22

7
COPPER CONDUCTOR TERMINATIONS

REDUCING LINKS
• Solid drawn copper rod
• Electro tin plated • Stock sizes shown
• Custom sizes to order
• Crimp with standard Utilux hex dies

LARGE END SMALL END


CONDUCTOR DIMENSIONS: CRIMPING DIMENSIONS: CRIMPING
DESCRIPT.
AREA mm2 A B ID DIE C ID DIE
CKR16-6 16-6 55 27 5.5 28 3.7 38-44CU
38-63CU
CKR16-10 16-10 55 27 5.5 28 4.5 38-57CU
CKR25-6 25-6 56 27 7.2 29 3.7 38-44CU
CKR25-10 25-10 56 27 7.2 38-77CU 29 4.5 38-57CU
CKR25-16 25-16 56 28 7.2 29 5.5 38-63CU
CKR35-10 35-10 56 27 8.5 29 4.5 38-57CU
CKR35-16 35-16 56 28 8.5 38-92CU 29 5.5 38-63CU
CKR35-25 35-25 56 28 8.5 28 7.2 38-77CU
CKR50-16 50-16 58 28 9.5 30 5.5 38-63CU
CKR50-25 50-25 58 28 9.5 38-104CU 30 7.2 38-77CU
CKR50-35 50-35 58 29 9.5 30 8 38-92CU
CKR70-25 70-25 58 28 11.0 30 7.2 38-77CU
CKR70-35 70-35 58 29 11.0 38-115CU 30 8.5 38-92CU
CKR70-50 70-50 58 29 11.0 30 9.5 38-104CU
CKR95-35 95-35 75 29 13.5 46 8.5 38-92CU
CKR95-50 95-50 75 29 13.5 38-142CU 46 9.5 38-104CU
CKR95-70 95-70 75 30 13.5 46 11.0 38-115CU
CKR120-50 120-50 75 29 15 46 9.5 38-104CU
CKR120-70 120-70 75 30 15 38-165CU 46 11.0 38-115CU
CKR120-95 120-95 88 44 15 44 13.5 38-142CU
CKR150-70 150-70 77 30 16.5 48 11.0 38-115CU
CKR150-95 150-95 90 44 16.5 38-183CU 46 13.5 38-142CU
CKR150-120 150-120 90 44 16.5 46 15 38-165CU
CKR185-95 185-95 90 44 18.5 46 13.5 38-142CU
CKR185-120 185-120 90 44 18.5 38-200CU 46 15 38-165CU
CKR185-150 185-150 90 45 18.5 45 16.5 38-183CU
CKR240-120 240-120 98 44 21.5 54 15 38-165CU
38-231CU
CKR240-150 240-150 98 45 21.5 53 16.5 38-183CU
40-231CU
CKR240-185 240-185 98 45 21.5 53 18.5 38-200CU
CKR300-150 300-150 98 45 24 53 16.5 38-183CU
38-260CU
CKR300-185 300-185 98 45 24 53 18.5 38-200CU
40-260CU
CKR300-240 300-240 101 50 24 51 21.5 38-231CU

Any size can be made for items not shown above –


complete Utilux Express form on page 103 and fax to our manufacturing site on (02) 4353 2470

8
COPPER CONDUCTOR TERMINATIONS

COPPER STALK LUG – TYPE 1


• Electro tinned finish
• Alternative sizes made to order

CONDUCTOR STRANDING DIMENSIONS (mm) CRIMPING


DESCRIPT. CAT NO.
AREA mm2 METRIC A B D F DIE
CS1-35/8 H2309 35 19/1.53 70 8 34 25 38-92CU
CS1-50/8 H2313 50 19/1.78 70 8 34 25 38-104CU 1
CS1-70/10 H2317 70 19/2.14 70 10 34 25 38-115CU
CS1-95/10 H2331 95 37/1.78 70 10 34 25 38-142CU
CS1-120/16 H2314 120 37/2.03 73 16 38 25 38-165CU
CS1-150/16 H2318 150 37/2.25 73 16 38 25 38-183CU
CS1-185/12 H2319 185 37/2.52 73 12 38 25 38/40-200CU
CS1-185/16 H2321 185 37/2.52 73 16 38 25 38/40-200CU

Note: Conductor areas indicated for STYLE 1 are combined areas of wire to be spliced

COPPER STALK LUG – TYPE 2


• Electro tinned finish
• Alternative sizes made to order

CONDUCTOR STRANDING DIMENSIONS mm CRIMPING


DESCRIPT. CAT NO.
AREA mm2 METRIC A B D F DIE
CS2-16/8 H2341 7/1.70 52 8 22 22
16 38-63CU
CS2-16/10 H2342 7/1.70 67 10 34 22
CS2-25/10 H2345 19/1.35 67 10 34 22
25 38-77CU
CS2-25/16 H2346 19/1.35 70 16 38 22
CS2-35/10 H2325 19/1.53 70 10 34 22
CS2-35/12 H2326 35 19/1.53 70 12 34 22 38-92CU
CS2-35/16 H2327 19/1.53 70 16 34 22
CS2-50/10 H2350 19/1.78 70 10 34 22
50 38-104CU
CS2-50/16 H2351 19/1.78 73 16 38 22
CS2-70/16 H2328 70 19/2.14 73 16 38 22 38-115CU
CS2-95/16 H2354 95 37/1.78 70 16 34 22 38-142CU

9
COPPER CONDUCTOR TERMINATIONS

CABLE LUG SOLDER TYPE


• Solid drawn copper tube • Electro tinned • Alternative sizes made to order
• Not recommended for crimping • Bright acid tin finish for easy solderability

MAX AREA NOMINAL AMPS STUD DIMENSIONS mm


DESCRIPT. CAT NO.
mm2 FOR CU CABLE SIZE E A B C D F I.D.
SG10 H201 10 75 M5 28.6 8.9 1.8 8.9 9.5 4.5
SG16 H202 16 99 M6 38.6 11.9 1.6 16.0 17.0 6.1
SG35 H203 25-35 155 M8 38.1 16.0 1.8 16.5 12.7 9.3
SG50 H204 50 250 M10 44.5 18.5 2.4 20.5 15.9 10.3
SG70 H205 70 310 M10 56.0 23.1 3.3 27.5 17.9 12.6
SG95 H206 95 375 M12 68.0 28.0 3.3 33.5 20.6 15.8
SG120 H207 120 435 M16 79.5 33.0 3.3 36.0 22.2 19.0
SG150 H208 150 570 M20 85.7 37.6 4.0 36.0 28.6 21.3
SG185 H209 185-240 680 M20 106.5 46.5 5.3 48.0 37.0 26.5

SEALED COPPER CRIMP LUGS


• Long barrel length for effective heat shrink sealing
• Designed for outdoor terminations
• Solder sealed • Impervious to air at 140 kPa min

CONDUCTOR STRANDING STUD DIMENSIONS (mm) CRIMPING


DESCRIPT. CAT NO.
AREA mm2 METRIC SIZE A B C DIE
SEG25M8 H16011 M8 14.7 19 29
25 7/2.14-19/1.35 38-77CU
SEG25M10 H16012 M10 16.7 19 29
SEG35M8 H16014 M8 18.2 19 35
SEG35M10 H16015 35 19/1.53 M10 18.2 19 35 38-92CU
SEG35M12 H16016 M12 20.0 24.5 35
SEG50M10 H16018 M10 19.0 27 38
50 19/1.78 38-104CU
SEG50M12 H16019 M12 20.6 27 38
SEG70M10 H16021 M10 20.6 27 43
70 19/2.14 38-115CU
SEG70M12 H16022 M12 20.6 27 43
SEG95M10 H16023 M10 25.4 27 53
95 19/2.52 38-142CU
SEG95M12 H16024 M12 25.4 27 53
SEG120M10 H16026 M10 30.0 31.8 62
120 37/2.03 38/40-165CU
SEG120M12 H16027 M12 30.0 31.8 62
SEG150M12 H16029 M12 33.5 41.3 67
150 37/2.25 3/40-183CU
SEG150M16 H16030 M16 33.5 41.3 67
SEG185M12 H16032 M12 36.5 41.3 77
185 37/2.52 38/40-200CU
SEG185M16 H16033 M16 36.5 41.3 77
SEG240MB H16035 MB 41.6 54 86
240 61/2.25 38/40-231CU
SEG240M12 H16036 M12 41.6 54 86
SEG300MB H16038 MB 46.0 54 95
300 61/2.52 38/40-260CU
SEG300M16 H16039 M16 46.0 54 95
SEG400MB H16041 MB 49.6 54 105
400 61/2.85 40/66-281CU
SEG400M16 H16042 M16 49.6 54 105
SEG500MB H16044 MB 54.8 54 115
500 61/3.20 40/66-310CU
SEG500M20 H16045 M20 54.8 54 115
SEG630MB H16047 MB 63.5 54 133
630 127/2.52 40-370
SEG630M20 H16048 M20 63.5 54 133

10
COPPER CONDUCTOR TERMINATIONS

LONG PALM LONG BARREL COPPER CRIMP LUGS


• Long barrel length for effective heat shrink sealing • No inspection window
• Uses same crimp tools as standard copper lugs

1
DESCRIPT. CONDUCTOR DIMENSIONS mm CRIMPING
P/N AREA mm2 C D E F L DIE
CG16LPMB 16 13 1.9 70 40 114 38-63CU
CG25LPMB 25 17 1.9 70 40 115 38-77CU
CG35LPMB 35 18 2.7 90 45 140 38-92CU
CG50LPMB 50 21 2.8 100 50 160 38-104CU
CG70LPMB 70 21 3.2 100 50 160 38-115CU
CG95LPMB 95 25 4.0 100 50 160 38-142CU
CG120LPMB 120 30 4.8 100 50 160 38-165CU
CG150LPMB 150 34 5.4 100 50 170 38-183CU
CG185LPMB 185 37 5.4 100 55 170 38-200CU
CG240LPMB 240 42 7.1 110 60 190 38-231CU
CG300LPMB 300 46 7.9 110 60 190 40-260CU
CG400LPMB 400 50 7.9 110 70 210 40-281CU
CG500LPMB 500 55 8.2 110 70 210 40-310CU
CG630LPMB 630 64 11.5 100 70 205 40-370CU

CAST LUGS
• Made to custom requirements
• Made to approved order, quantities only
• Copper alloy, however can be made in other materials
• Type of applications; – diesel electric loco
– transformers – special application

11
COPPER CONDUCTOR TERMINATIONS

BOLTED CABLE LUG


• Quick and easy termination • Re-usable
• Palms are machined flat and parallel for maximum conductivity
• Copper alloy

GENERIC CONDUCTOR NON FLEXIBLE STUD DIMENSIONS mm


DESCRIPT. CAT NO.
CODE AREA mm2 CONDUCTOR SIZE A B C D
7/.085
BG1 H1801 NO. 1 4-10 7/1.04 M6 34 14 5.5 17
7/1.35
BG2 H1802 NO. 2 16 7/1.70 M8 44 19 5.5 23
BG3 H1803 7/2.14 M10
BG3A H1803A NO. 3 25-35 19/1.53 M12 53 25 5.5 27

19/1.78
BG4 H1804 NO. 4 50-70 19/2.14 M12 60 32 6.4 34

19/1.78
BG4C* H1804C NO. 4C 50-70 19/2.14 M12 60 32 6.4 34

BG5 H1805 NO. 5 95 37/1.78 M12 65 32 7.9 38


BG6A H1806A NO. 6 120 37/2.03 M16 76 38 8.7 45
37/2.25
BG6 H1806 NO. 6 150-185 37/2.52 M16 76 38 8.7 45

BG7 H1807 NO. 7 185-240 61/2.25 M20 86 44 10.3 53


61/2.52
BG8 H1808 NO. 8 300-400 61/2.85 M20 98 51 12.7 63

BG9 H1809 NO. 9 500 61/3.20 M20 100 48 13.5 70


*C = Slot 12mm wide instead of bolt hole

BOLTED TEE CLAMP


• Provide quick and easy tee offs
• Copper alloy
• H1820 and H1821 can be used with slotted
palm lugs for easy disconnect facility

MAIN CABLE RANGE TEE CABLE RANGE DIMENSIONS


DESCRIPT. CAT NO.
MIN MAX MIN MAX A B
TG185240 H1818 185mm2 240mm2 70mm2 95mm2 81 33
TG5070 H1820 50mm 2
70mm 2
- - 79 32
TG7095 H1821 70mm2 95mm2 - - 87 70

12
COPPER CONDUCTOR TERMINATIONS

‘C’ CONNECTORS

C-Connectors are manufactured in ‘C’ shaped copper section

for connection of main and tap copper conductors.


W
• Reliability is ensured by passing tests

specified by JIS C 2810


H C
1
• Suitable for connecting copper conductors in both indoor

and outdoor applications such as earth grid connections

• Tin plated • Other sizes available on request (366-700mm2) L = Connector Length

CONDUCTOR DIMENSIONS INSULATING


DESCRIPT. Die Part No.
CAT NO. RANGE mm2 H W L C COVER
CC10 T-011 7.5 to 11 9 6 12 4 #18C -
CC16 T-016 11.5 to 16 12 8 13 5 #18C -
CC20 T-020 14 to 20 13 10 13 5 38-T020 T-020C
CC25 T-026 21 to 26 15 11 16 6 38-T026 T-026C
CC35 T-044 27 to 44 19 14 20 8 38-T044 T-044C
CC50 T-060 45 to 60 21 15 22 10 38-T060 T-060C
CC70 T-076 61 to 76 24 17 22 11 38-T076 T-076C
CC95 T-098 77 to 98 28 19 25 14 38-T098 T-098C
CC120 T-122 99 to 122 30 21 26 13 38-T122 T-122C
CC150 T-154 123 to 154 34 24 28 17 38-T154 T-154C
CC185 T-190 155 to 190 37 25 35 17 38-T190 T-190C
CC240 T-240 191 to 240 40 28 40 19 38-T240 T-240C
CC300 T-288 241 to 288 45 31 45 22 38-T288 T-288C
CC400 T-365 289 to 365 48 34 50 24 38-T365 T-365C

C O N D U C T O R T A P mm2
2.5 4 6 10 16 20 25 35 50 70 95 120 150 185 240 300 400

6 11 11 16
10 16 16 16
mm2

16 20 20 26 26 44
20 26 26 26 44 44 44
C O N D U C T O R

25 44 44 44 44 44 60 60
35 44 44 44 60 60 60 60 76
50 60 60 60 60 76 76 76 98 122
70 76 76 76 98 98 98 98 122 122 154
95 98 122 122 122 122 122 122 154 154 190 190
120 154 154 154 154 154 154 154 190 190 190 240 240
150 154 154 190 190 190 190 190 190 240 240 288 288 365
M A I N

185 190 190 240 240 240 240 240 240 240 288 288 365 365 450
240 288 288 288 288 288 288 365 365 365 365 450 450 560
300 365 365 365 365 365 365 365 450 450 450 450 560 560 700
400 450 450 560 560 560 560 700 700 700
500 560 560 700 700 700 700 700
630 700 700 700

13
COPPER CONDUCTOR TERMINATIONS

SOLID PALM COPPER LUGS

Utilux have introduced a range of small copper lugs to be used in heavy

industry. The range of connectors (6sqmm to 35sqmm) compliments the

existing larger size copper cast lugs. The lugs are fabricated from copper

rod to maximise the strength. They are made without a seam in the palm,

with an increased wall thickness and electro-tinned plated. The solid palm

also eliminates the ingress of moisture which makes them suitable for

outdoor use. Crimping has been rationalised so that only two (2) sets of

dies are required to terminate the

full range of lugs.

TYPICAL APPLICATIONS

• Overhead connections for electrical distribution systems

• Railway electrification systems where vibration is a concern

• Other sizes available on request

CONDUCTOR BOLT DIMENSIONS mm


CAT NO. CRIMPING DIE
AREA mm2 SIZE A B C D F
CG6SDM6 M6 51 16 4.2 21 23
CG6SDM8 6 M8 51 16 4.2 21 23
CG6SDM10 M10 51 16 4.2 21 23
38-77CU
CG10SDM6 M6 51 16 4.2 21 23
CG10SDM8 10 M8 51 16 4.2 21 23
CG10SDM10 M10 51 16 4.2 21 23
CG16SDM8 M8 70 21 6.0 27 30
CG16SDM10 16 M10 70 21 6.0 27 30
CG16SDM12 M12 70 21 6.0 27 30
CG25SDM10 M10 70 21 6.0 27 30 38-104CU
25
CG25SDM12 M12 70 21 6.0 27 30
CG35SDM10 M10 70 21 6.0 27 30
35
CG35SDM12 M12 70 21 6.0 27 30

14
CONTENTS

ALUMINIUM LUGS AND LINKS SECTION 2

SECTION 2 ALUMINIUM LUGS AND LINKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15


UNILUG FOR ALUMINIUM CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
UNILINK ALUMINIUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
ELECTRICAL JOINTING COMPOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3 & 4 CORE SECTOR LUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
ROUND BARREL SECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3 & 4 CORE SECTOR LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
SECTOR TO ROUND LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
CCT CONDUCTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
ALUMINIUM ROTATING LUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

CATALOGUE INDEX INDEX


ALUMINIUM LUGS & LINKS

UNILUG FOR ALUMINIUM CABLES


• 99.9% pure high conductivity aluminium
• Forged from solid AL billets
• Solid palm, therefore eliminating the ingress of moisture
• Pre-filled with joining compound
• Individually packed in sealed plastic bags

CONDUCTOR STRANDING STUD DIMENSIONS mm CRIMPING


DESCRIPT. CAT NO.
AREA mm2 METRIC SIZE E A B C D F I.D. DIE
AG6MB H15100 MB
6 7/1.04 54 18 5 22 32 3.5
AG6M6 H15101 M6
AG10MB H15103 MB
10 7/1.35 65 22 5 22 32 4.5
AG10M6 H15104 M6
AG16MB H15106 MB
16 7/1.70 65 22 5 22 32 5.5 38-90AL
AG16M10 H15109 M10
AG25MB H15111 7/2.14 MB
25 65 22 5 22 32 7.0
AG25M10 H15114 19/1.35 M10
AG35MB H15116 MB
35 19/1.53 65 22 5 22 32 8.5
AG35M10 H15119 M10
AG50MB H15121 MB
50 19/1.78 73 26 8 28 32 9.5
AG50M10 H15124 M10
AG70MB H15126 MB 38-132AL
AG70M10 H15129 70 19/2.14 M10 73 26 8 28 32 11.0
AG70M12 H15130 M12
AG95MB H15131 MB
19/2.52
AG95M10 H15134 95 M10 80 30 10 35 32 13.0
37/1.78
AG95M12 H15135 M12 38-173AL
AG120MB H15136 MB 40-172AL
AG120M10 H15138 120 37/2.03 M10 80 30 10 35 32 15.0
AG120M12 H15139 M12
AG150MB H15141 MB
AG150M10 H15142 M10
150 37/2.25 90 36 11 36 30 16.5
AG150M12 H15143 M12
AG150M16 H15144 M16 38-220AL
40-220AL
AG185MB H15146 MB
AG185M12 H15147 185 37/2.52 M12 90 36 11 36 30 18.5
AG185M16 H15148 M16
AG240MB H15151 MB
AG240M12 H15153 240 61/2.25 M12 115 46 12 50 37 21.0
AG240M16 H15154 M16 38-284AL
AG300MB H15156 MB 40-283AL
115 46 12 50 41 23.5
AG300M12 H15159 300 61/2.52 M12
AG300M16 H15160 M16
AG400MB H15162 MB
AG400M12 H15165 400 61/2.85 M12 150 54 15 54 68 26.5
AG400M16 H15166 MB
40-390AL
AG500MB H15168 MB
AG500M12 H15171 500 61/3.20 M12 150 54 15 54 68 29.5
AG500M16 H15172 M16
AG630MB H15174 MB
630 127/2.52 159 60 15 60 68 33.5 40-432AL
AG630M16 H15176 M16

Stud size “MB” means blank palm.


800-1000mm2 tube Aluminium Crimp Lugs made to approved minimum order quantities only.

16
ALUMINIUM LUGS & LINKS

UNILINK ALUMINIUM
• Solid barrier
• High conductivity Aluminium
• Prefilled with jointing compound
• Individually packed in sealed plastic bags

CONDUCTOR STRANDING DIMENSIONS CRIMPING


DESCRIPT. CAT NO.
AREA (mm2) METRIC A (mm) B (mm) DIE
AK6 H15200 6 7/1.04 70 3.5
AK10 H15201 10 7/1.35 70 4.5 2
AK16 H15202 16 7/1.70 70 5.5 38-90AL
AK25 H15203 25 7/2.14 - 19/1.35 70 7.0
AK35 H15204 35 19/1.53 70 8.5
AK50 H15205 50 19/1.78 70 9.5
38-132AL
AK70 H15206 70 19/2.14 70 11.0
AK95 H15207 95 19/2.52 - 37/1.78 124 13.0 38-173AL
AK120 H15208 120 37/2.03 124 15.0 40-172AL
AK150 H15209 150 37/2.25 124 16.5 38-220AL
AK185 H15210 185 37/2.52 124 18.5 40-220AL
AK240 H15211 240 61/2.25 124 21.0 38-284AL
AK300 H15212 300 61/2.52 124 23.5 40-283AL
AK400 H15213 400 61/2.85 146 26.5
40-390AL
AK500 H15214 500 61/3.20 146 29.5
AK630 H15215 630 127/2.52 146 33.5
40-432AL
AK800 H15216 800 127/2.85 260 38.5

Larger sizes available, subject to approved quantities.

ELECTRICAL JOINTING COMPOUND


• Recommended for Aluminium connections
• Zinc particles in H2397 penetrates oxide films that form on the Aluminium surface
• Seals out air and moisture, therefore minimising oxidation or corrosion
and maximising conductivity • High melt point grease

CAT NO. NO. APPLICATION PART COLOUR TUBE SIZE


H2397 4C Conductive compound Zn KD Grey 325g
with zinc particles

17
ALUMINIUM LUGS & LINKS

3 & 4 CORE SECTOR LUG


• Clear markings on barrel to indicate correct crimping sequence
• Prefilled with jointing compound • Supplied with flat washers
• Suit 3 core 1200 or 4 core 900 solid sector
aluminium conductor
• 99.9% pure, high conductivity Aluminium
• Individually packed in sealed plastic bags

CONDUCTOR STUD DIMENSIONS mm TOOL DIES


DESCRIPT. CAT NO.
AREA mm2 SIZE E A B C D F NO. NEST INDENT
3 CORE
AGS120M12 H8610 120 M12 100 31 6.9 33.5 51 38A 12 16
AGS150M12 H8611 150 M12 103 35 7.3 33.5 51 38A 12 17
AGS185M12 H8613 185 M12 115 38 7.3 37.3 59 38A 12 18
AGS240M12 H8615 240 M12 123 42 8.7 37.3 63 38A 12 19
AGS240M16 H8616 240 M16 123 42 8.7 37.3 63 38A 12 19
4 CORE
AGI120M12 H8889 120 M12 101.6 32 6.7 34.9 53.9 38A 14 16
AGI150M12 H8890 150 M12 110.3 35 7.1 34.9 59.5 38A 14 17
AGI185M12 H8891 185 M12 115.0 40 8.3 38.1 59.5 38A 14 18
AGI240M12 H8892 240 M12 127.8 46 11.7 44.4 62.6 38A 15 19

ROUND BARREL SECTOR


• 99.9% pure high conductivity aluminium • Forged from solid AL billets
• Solid palm, therefore eliminating the ingress of moisture
• Pre-filled with joining compound
• Individually packed in sealed plastic bags
• Hexcrimp with std Utilux dies

DIMENSIONS mm
DESCRIPT. CAT NO.
A B C D F CRIMPING DIE
AG4H185M12 H50804 115 36 11 36 62 38-220AL 40-220AL
AG4H240M12 H50805 133 36 12 36 62 38-284AL 40-283AL

18
ALUMINIUM LUGS & LINKS

3 & 4 CORE SECTOR LINK


• Clear markings on barrel to indicate correct crimping sequence
• Prefilled with jointing compound
• Suit 3 core 1200 or 4 core 900 solid sector
aluminium conductor
• 99.9% pure, high conductivity aluminium
• Individually packed in sealed plastic bags

CONDUCTOR mm TOOL DIES


DESCRIPT. CAT NO.
AREA mm2 A NO. NEST INDENT 2
3 CORE
AKS120 H8627 120 90 38A 12 16
AKS150 H8628 150 90 38A 12 17
AKS185 H8629 185 105 38A 12 18
AKS240 H8630 240 110 38A 12 19
4 CORE
AKI120 H8949 120 88.9 38A 14 16
AKI150 H8950 150 104.8 38A 14 17
AKI185 H8951 185 104.8 38A 14 18
AKI240 H8952 240 114.3 38A 15 19

SECTOR TO ROUND LINK


• Clear markings on barrel to indicate correct crimping sequence
• Prefilled with jointing compound
• Suit 3 core 1200 or 4 core 900 solid sector
aluminium conductor
• 99.9% pure, high conductivity aluminium
• Individually packed in sealed plastic bags

DESCRIPT. CONDUCTOR OVERALL ROUND END SECTOR CRIMP


P/N SECTOR mm2 ROUND mm2 LENGTH HEXCRIMP DIE NEST DIE INDENT DIE
3 CORE
AK3I185240 185 240 150 38-284AL #12 NEST #18 INDENT
AK3I240300 240 300 150 38-284AL #15 NEST #20 INDENT
4 CORE
AK4I240300 240 300 153 38-284AL #15 NEST #20 INDENT

19
ALUMINIUM LUGS & LINKS

CCT CONDUCTOR

The new aluminium lugs & links are designed for use with 7/2.75 (40mmsq)

Aluminium CCT conductor.

The lug is primarily used on dropper cables for pole mounted substations. An

aluminium link is also provided for in line connections.

The lug and link are manufactured from 99.9% pure high conductivity aluminium. They

are forged to maximise conductivity and strength.

The solid palm also eliminates the ingress of moisture whilst the plating gives added

protection for outdoor use.

The lug and link are pre-filled with jointing compound, ink stamped with catalogue

number and crimping details and individually packed in sealed plastic bags.

CAT CONDUCTOR DIMENSIONS mm CRIMPING


NO. SIZE A B C D E F DIE
7/2.75
LUG AG40M10ET 73 26 8 28 M12 32 38-132AL
(40mmSQ)
7/2.75
LUG AG40M12ET 70 26 8 28 M12 32 38-132AL
(40mmSQ)
7/2.75
LINK AK40ET 70 N/A N/A N/A N/A N/A 38-132AL
(40mmSQ)

ver you nee


e
d
t
wha

P
L

C
AN HE

20
ALUMINIUM LUGS & LINKS

A NEW SOLUTION FOR CONNECTING


UNDERGROUND ALUMINIUM CABLES

This new range of connectors for aluminium 4 core sector cable features a

unique concept enabling the lug to be rotated to any desired position on the

conductor, without the need to round the conductor first. The design

embodies the tried and proven round barrel/hex compression die

combination, giving superior connection reliability.

BENEFITS: • The lug can be rotated to any desired position


2
• No need to twist conductor to correct orientation

• Minimum effort required to correctly orientate lug

• Reduces total connection time

• Suits solid and stranded conductor types

• Uses standard size hexagonal dies

• No need to round the sector cable first

• Bi-metal versions available

• No voids when crimped

• Takes two crimps on the barrel without overlapping

• Palm will fit into most receptacles found in URD system

• Supplied pre-packed with jointing compound, in sealed plastic bags

• The lug barrel has markings showing the length of insulation to be stripped

• Made from high conductivity, high strength, solid forged aluminium

• Tested to BS4579

ALUMINIUM ROTATING LUGS


CONDUCTOR DIMENSIONS mm STUD CRIMPING
DESCRIPT. CAT NO.
AREA mm2 A F OD B C D E DIE
AG4HR185MB H15353 185 112 50 34 36 12 36 MB
AG4HR185M12 H15354 185 112 50 34 36 12 36 M12 38-284AL
AG4HR185M16 H15355 185 112 50 34 36 12 36 M16
AG4HR240MB H15356 240 112 50 34 36 12 50 MB
AG4HR240M12 H15357 240 112 50 34 36 12 50 M12 38-284AL
AG4HR240M16 H15358 240 112 50 34 36 12 50 M16

21
CONTENTS

BI-METAL LUGS AND LINKS SECTION 3

SECTION 3 BI-METAL LUGS AND LINKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23


BI-METAL CRIMP LUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
BI-METAL CRIMP LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
3 & 4 CORE SECTOR
BI-METAL LUG – (SOLID ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
3 & 4 CORE SECTOR
BI-METAL LINK – (SOLID ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
BI-METAL CRIMP STALK LUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
3 & 4 CORE SECTOR
BI-METAL STALK – (SOLID ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
BI-METAL ROTATING LUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
BI-METAL ROTATING LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
BI-METAL LONG PALM LUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
BI-METAL REVERSE LUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

CATALOGUE INDEX INDEX


BI-METAL LUGS & LINKS

BI-METAL CRIMP LUG


• For aluminium to copper terminations • Friction welded
• Manufactured from high purity copper and aluminium rod
• Stepped barrel OD sizes across all bi-metal allows rationalisation of die inventory
• Pre-filled with jointing compound • Individually packed in sealed plastic bags
• Reverse bi-metal (aluminium palm, copper barrel)
lugs are manufactured to approved order quantities
• Alternative sizes can be made to order for
approved order quantities

CONDUCTOR STRANDING DIMENSIONS mm STUD PALM CRIMPING


DESCRIPT. CAT NO.
AREA mm2 METRIC A B C D E SIZE F THICK DIE
BG16MB H15304 MB
16 7/1.70 75.0 32.0 12.0 5.5 22.0 4.5
BG16M10 H15305 M10
BG25MB H15306 MB
25 19/1.35 75.0 32.0 12.0 7.0 22.0 4.5
BG25M10 H15307 M10
38-90AL
BG35MB H15308 MB
BG35M10 H15309 35 19/1.53 75.0 32.0 12.0 8.5 22.0 M10 4.5
BG35M12 H15310 M12
BG50MB H15311 MB
BG50M10 H15312 50 19/1.78 75.0 32.0 16.0 9.5 22.0 M10 4.5
BG50M12 H15313 M12
38-132AL
BG70MB H15314 MB
BG70M10 H15315 70 19/2.14 75.0 32.0 16.0 11.0 22.0 M10 4.5
BG70M12 H15316 M12
BG95MB H15317 MB
BG95M10 H15318 95 37/1.78 115.0 60.0 21.5 13.0 32.0 M10 6.0
BG95M12 H15319 M12 38-173AL
BG120MB H15320 MB 40-172AL
BG120M12 H15321 120 37/2.03 115.0 60.0 21.5 15.0 32.0 M12 6.0
BG120M16 H15322 M16
BG150MB H15323 MB
BG150M12 H15324 150 37/2.25 120.0 60.0 27.0 16.5 36.0 M12 7.0
BG150M16 H15325 M16 38-220AL
BG185MB H15326 MB 40-220AL
BG185M12 H15327 185 37/2.52 120.0 60.0 27.0 18.5 36.0 M12 7.0
BG185M16 H15328 M16
BG240MB H15329 MB
BG240M12 H15330 240 61/2.25 130.0 60.0 35.0 21.0 42.0 M12 7.0
BG240M16 H15331 M16 38-284AL
40-283AL
BG300MB H15332 MB
300 61/2.52 130.0 60.0 35.0 23.5 42.0 7.0
BG300M12 H15333 M12
BG400MB *H15334 400 61/2.85 160.0 70.0 47.0 26.5 50.0 MB 10.0
40-390AL
BG500MB *H15335 500 61/3.20 160.0 70.0 47.0 29.5 50.0 MB 10.0
BG630MB *H15336 630 127/2.52 175.0 70.0 54.0 33.5 60.0 MB 10.0
40-432AL
BG800MB *H15337 800 127/2.85 221.0 115.0 54.0 39.0 60.0 MB 10.0

*Square palms

24
BI-METAL LUGS & LINKS

BI-METAL CRIMP LINK


Suitable for aluminium to copper in line terminations
• Friction welded
• Manufactured for high purity copper and aluminium rod
• Prefilled with joint compound
• Individually packed in sealed plastic bags

ALUMINIUM COPPER
CONDUCTOR STRANDING DIMENSIONS mm CRIMPING. DIMENSIONS mm CRIMPING
3
DESCRIPT. CAT NO.
AREA mm2 METRIC A B C D DIE E J K DIE
BK16/10 H15404 16/10 7/1.70-7/1.35 4.5
70.0 32.0 12.0 5.5 38-90AL 11.5 21.5
BK16/16 H15405 16/16 7/1.70-7/1.70 5.5
BK25/16 H15406 25/16 19/1.35-7/1.70 5.5
70.0 32.0 12.0 7.0 38-90AL 11.5 21.5 38-92CU
BK25/25 H15407 25/25 19/1.35-19/1.35 7.0
BK35/25 H15408 35/25 19/1.53-19/1.35 7.0
70.0 32.0 12.0 8.5 38-90AL 11.5 21.5
BK35/35 H15409 35/35 19/1.35-19/1.53 8.5
BK50/35 H15410 50/35 19/1.78-19/1.53 11.5 8.5 38-92CU
70.0 32.0 16.0 9.5 38-132AL 21.5
BK50/50 H15411 50/50 19/1.78-19/1.78 14.5 9.5 38-115CU
BK70/50 H15412 70/50 19/2.14-19/1.78 9.5
70.0 32.0 16.0 11.0 38-132AL 14.5 21.5 38-115CU
BK70/70 H15413 70/70 19/2.14-19/2.14 11.0
BK95/70 H15414 95/70 37/1.78-19/2.14 110.0 38-173AL 14.5 32.0 11.0 38-115CU
60.0 21.5 13.0
BK95/95 H15415 95/95 37/1.78-37/1.78 120.0 40-172AL 20.5 40.0 13.0 38-165CU
BK120/95 H15416 120/95 37/2.03-37/1.78 38-173AL 13.0
120.0 60.0 21.5 15.0 20.5 40.0 38-165CU
BK120/120 H15417 120/120 37/2.03-37/2.03 40-172AL 15.0
BK150/120 H15418 150/120 37/2.25-37/2.03 20.5 40.0 15.0 38-165CU
120.0 60.0 27.0 16.5 38/40-220AL
BK150/150 H15419 150/150 37/2.25-37/2.25 24.5 16.5 38-200CU
BK185/150 H15420 185/150 37/2.52-37/2.25 16.5
120.0 60.0 27.0 18.5 38/40-220AL 24.5 40.0 38-200CU
BK185/185 H15421 185/185 37/2.52-37/2.52 18.5
BK240/185 H15422 240/185 61/2.25-37/2.52 122.0 60.0 35.0 21.0 38-284AL 24.5 40.0 18.5 38-200CU
BK240/240 H15423 240/240 61/2.25-61/2.25 125.0 40-283AL 32.0 21.0 38-260CU
BK300/240 H15424 300/240 61/2.52-61/2.25 125.0 60.0 35.0 23.5 38-284AL 32.0 40.0 21.0
38-260CU
BK300/300 H15425 300/300 61/2.52-61/2.52 40-283AL 23.5
BK400/300 H15426 400/300 61/2.85-61/2.52 153.0 70.0 47.0 26.5 32.0 55.0 23.5 40-260CU
40-390AL
BK400/400 H15427 400/400 61/2.85-61/2.85 155.0 38.5 58.0 26.5 40-310CU
BK500/400 H15428 500/400 61/3.20-61/2.85 38.5 58.0 26.5
155.0 70.0 47.0 29.5 40-390AL 40-310CU
BK500/500 H15429 500/500 61/3.20-61/3.20 29.5
BK630/500 H15430 630/500 127/2.52-61/3.20
160.0 70.0 54.0 33.5 40-432AL 45 60.0 33.5 40-310CU
BK630/630 H15431 630/630 127/2.52-127/3.20

25
BI-METAL LUGS & LINKS

3 & 4 CORE SECTOR


BI-METAL LUG – (solid only)
• Suitable for 3 or 4 core solid sector cable
• Clear markings on the barrel indicate the
crimping sequence
• Pre-filled with jointing compound
3 CORE 4 CORE
• Individually packed in sealed plastic bags
• Friction welded
• For aluminium to copper termination and
manufactured from high purity copper and aluminium rod

CONDUCTOR DIMENSIONS mm STUD PALM 38A DIES


DESCRIPT. CAT NO.
AREA mm2 A B C D E F THICK NEST INDENT
3 CORE
BGS120MB H15610 MB
120 111 49 10.6 18.1 32 6.0 12 16
BGS120M12 H15611 M12
BGS150MB H15612 MB
150 116 49 11.8 20.1 36 7.0 12 17
BGS150M12 H15613 M12
BGS185MB H15614 MB
185 126 57 13.2 22.5 36 7.0 12 18
BGS185M12 H15615 M12
BGS240MB H15616 MB
BGS240M12 H15619 240 138 61 15.2 25.8 42 M12 7.0 12 19
BGS240M16 H15617 M16
BGS300MB H15618 300 147 61 19.4 27.2 42 MB 7.0 12 21
4 CORE
BGI120MB H15660 MB
120 111 49 12.1 17.1 32 6.0 14 16
BGI120M12 H15661 M10
BGI185MB H15664 MB
185 126 57 15.1 21.2 36 7.0 14 18
BGI185M12 H15665 M12
BGI240MB H15666 MB
240 136 61 17.5 24.6 42 7.0 14 19
BGI240M12 H15667 M16
BGI300MB H15668 MB
300 147 61 19.4 27.2 42 7.0 15 21
BGI300M16 H15669 M16

26
BI-METAL LUGS & LINKS

3 & 4 CORE SECTOR


BI-METAL LINK – (solid only)
• Suitable for 3 or 4 core solid sector cable
• Clear markings on the barrel indicate the
crimping sequence
• Pre-filled with jointing compound
• Individually packed in sealed plastic bags
• Friction welded 3 CORE 4 CORE
• For aluminium to copper termination
• Manufactured from high purity copper and aluminium rod

ALUMINIUM COPPER
CAT. CONDUCTOR 38 DIES STRANDING DIMENSIONS CONDUCTOR CRIMPING
DESCRIPT.
NO. AREA mm2 AL NEST INDENT METRIC A B C D E J K AREA mm2 CU DIE
3 CORE
3
BKS120/70 H15710 120 12 16 19/2.14 106.0 49.0 10.6 18.1 14.5 32.0 11.0 70 38-115CU
BKS120/120 H15711 120 12 16 37/2.03 116.0 49.0 10.6 18.1 20.5 40.0 15.0 120 38-165CU
BKS150/95 H15712 150 12 17 37/1.78 116.0 49.0 11.8 20.1 20.5 40.0 13.0 95 38-165CU
BKS150/150 H15713 150 12 17 37/2.25 116.0 49.0 11.8 20.1 24.5 40.0 16.5 150 38-200CU
BKS185/120 H15714 185 12 18 37/2.03 126.0 57.0 13.2 22.5 20.5 40.0 15.0 120 38-165CU
BKS185/185 H15715 185 12 18 37/2.52 126.0 57.0 13.2 22.5 24.5 40.0 18.5 185 38-200CU
BKS240/150 H15716 240 12 19 37/2.25 131.0 61.0 15.2 25.8 24.5 40.0 16.5 150 38-200CU
BKS240/240 H15717 240 12 19 61/2.25 134.0 61.0 15.2 25.8 32.0 40.0 21.0 240 38-260CU
4 CORE
BKI70/50 H15756 70 14 14 19/1.78 88 43 9.0 13.5 14.5 22 9.5 50 38-115CU
BKI70/70 H15757 70 14 14 19/2.14 88 43 9.0 13.5 14.5 22 11.0 70 38-115CU
BKI95/70 H15758 95 14 15 19/2.14 106 49 10.5 14.8 14.5 32 11.0 70 38-115CU
BKI95/95 H15759 95 14 15 37/1.78 116 49 10.5 14.8 20.5 40 13.0 95 38-165CU
BKI120/70 H15760 120 14 16 19/2.14 106 49 12.1 17.1 14.5 32 11.0 70 38-115CU
BKI120/120 H15761 120 14 16 37/2.03 116 49 12.1 17.1 20.5 40 15.0 120 38-165CU
BKI150/95 H15762 150 14 17 37/1.78 116 49 13.6 19.1 20.5 40 13.0 95 38-165CU
BKI150/150 H15763 150 14 17 37/2.25 116 49 13.6 19.1 24.5 40 16.5 150 38-200CU
BKI185/120 H15764 185 14 18 37/2.03 126 57 15.1 21.2 20.5 40 15.0 120 38-165CU
BKI185/185 H15765 185 14 18 37/2.52 126 57 15.1 21.2 24.5 40 18.5 185 38-200CU
BKI240/150 H15766 240 14 19 37/2.25 131 61 17.5 24.6 24.5 40 16.5 150 38-200CU
BKI240/240 H15767 240 14 19 61/2.25 134 61 17.5 24.6 32.0 40 21.0 240 38-260CU
BKI300/185 H15768 300 14 21 37/2.52 140 61 19.4 27.2 24.5 40 18.5 185 38-200CU
BKI300/300 H15769 300 14 12 61/2.52 143 61 19.4 27.2 32.0 40 23.5 300 38-260CU

27
BI-METAL LUGS & LINKS

BI-METAL CRIMP STALK LUG


• Suitable for aluminium to copper terminations
• Friction welded
• Manufactured from high purity
copper and aluminium
• Prefilled with jointing compound
• Individually packed in sealed plastic bags

CAT. CONDUCTOR STRANDING CRIMPING


DESCRIPT.
NO. AREA mm2 METRIC A B C D L M DIE
BS16/12 H15502 16 7/1.70 70 32 12 5.5 30 12
BS25/12 H15503 25 19/1.35 70 32 12 7.0 30 12 38-90AL
BS35/12 H15504 35 19/1.53 70 32 12 8.5 30 12
BS50/12 H15505 50 19/1.78 70 32 16 9.5 30 12
38-132AL
BS70/12 H15506 70 19/2.14 70 32 16 11.0 30 12

BS95/12 H15507 95 37/1.78 110 60 21.5 13.0 38 12


38-173AL
BS120/12 H15508 12 40-172AL
BS120/14 H15509 120 37/2.03 110 60 21.5 15.0 38 14
BS150/12 H15510 12
BS150/14 H15511 150 37/2.25 120 60 27 16.5 48 14 38-220AL
BS185/16 H15512 16 40-220AL
BS185/18 H15513 185 37/2.25 120 60 27 18.5 48 18
BS240/16 H15514 16
BS240/18 H15515 240 61/2.25 122 60 35 21.0 48 18 38-284AL
BS300/16 H15516 16 40-283AL
BS300/18 H15517 300 61/2.52 122 60 35 23.5 48 18
BS400/18 H15518 18
BS400/20 H15519 400 61/2.85 153 70 47 26.5 65 20
40-390AL
BS500/18 H15520 18
BS500/20 H15521 500 61/3.20 153 70 47 29.5 65 20

BS630/20 H15522 630 127/2.52 160 70 54 33.5 70 20 40-432AL

Alternative stalk sizes can be manufactured to approved minimum order quantities

3 & 4 CORE SECTOR


BI-METAL STALK – (solid only)
•Suitable for 3 or 4 core solid sector cable
• Clear markings on the barrel indicate the
crimping sequence
• Prefilled with jointing compound 3 CORE 4 CORE
• Individually packed in sealed plastic bags
• Friction welded
• For aluminium to copper terminations
• Manufactured from high purity copper and aluminium rod

CONDUCTOR 38A DIES


DESCRIPT. CAT NO.
AREA mm2 A B C D L M NEST INDENT
3 CORE
BSS240/16 H15816 240 134 61 15.2 25.8 48.0 16.0 12 19
4 CORE
BSI70/12 H15856 70 88 43 9.0 12.5 30 12 14 14
BSI95/12 H15858 95 108 49 10.5 14.8 38 12 14 15
BSI120/12 H15860 120 118 49 12.1 17.1 48 12 14 16
BSI150/12 H15862 150 119 49 13.6 19.1 48 12 14 17
BSI185/16 H15864 185 129 57 15.1 21.2 48 16 14 18
BSI240/16 H15866 240 134 61 17.5 24.6 48 16 14 19
BSI300/16 H15868 300 143 61 19.4 27.2 48 16 14 21

28
BI-METAL LUGS & LINKS

ROTATING BI-METAL LUGS & LINK


This new range of connectors for aluminium 4 core sector cable features a unique concept enabling the lug to be
rotated to any desired position on the conductor, without the need to round the conductor first. The design embodies
the tried and proven round barrel/hex compression die combination, giving superior connection reliability.

BENEFITS:
• The lug can be rotated to any desired position
• No voids when crimped
• No need to twist conductor to correct orientation
• Takes two crimps on the barrel without overlapping
• Minimum effort required to correctly orientate lug
• Palm will fit into most receptacles found in URD system
• Reduces total connection time
• Supplied pre-packed with jointing compound, in sealed plastic bags
• Suits solid and standard conductor types
• The lug barrel has markings showing the length of insulation to be stripped
• Uses standard size hexagonal dies
• Made from high conductivity, high strength, solid forged aluminium
• No need to round the sector cable first 3
• Tested to BS4579

CONDUCTOR DIMENSIONSmm PALM STUD CRIMPING


DESCRIPT. CAT NO.
AREA mm2 A B E THICK F DIE
BG4HR185MB H15362 185 119 50 36 7.0 MB 38-284AL
BG4HR185M12 H15363 185 119 50 36 7.0 M12 38-284AL
BG4HR185M16 H15364 185 119 50 36 7.0 M16 38-284AL
BG4HR240MB H15365 240 126 50 42 7.0 MB 38-284AL
BG4HR240M12 H15366 240 126 50 42 7.0 M12 38-284AL
BG4HR240M16 H15367 240 126 50 42 7.0 M16 38-284AL

ALUMINIUM COPPER
CONDUCTOR DIMENSIONS mm CRIMPING DIMENSIONS mm CRIMPING
DESCRIPT.
AREA mm2 A B DIE E J K DIE
BK4HR240150 240 150 110 50 38-284AL 24.5 40 16.5 38-200CU
4 core sector

29
BI-METAL LUGS & LINKS

BI-METAL LONG PALM LUGS


• For two bolt termination applications • Blank palm, 105mm long x 50mm wide
• Friction welded high purity aluminium and copper rod • Eliminates electrolytic corrosion
• Clearly marked with cable size, die recommendation and crimping position • Pre-filled with jointing compound
• Individually packed in plastic bags • Palms can be drilled to customers bolt hole specification

CONDUCTOR DIMENSIONS mm CRIMPING


DESCRIPT.
AREA mm2 A B C D E F G DIE
BG240LPMB 240 209 60 35 21 50 13 105
38-284AL
BG300LPMB 300 209 60 35 23.5 50 13 105
BG400LPMB 400 221 70 47 26.5 50 13 105
40-390AL
BG500LPMB 500 221 70 47 29.5 50 13 105
BG630LPMB 630 221 70 54 33.5 50 13 105
40-432AL
BG800LPMB 800 266 105 54 39 50 13 105

BI-METAL REVERSE LUGS


• Used for connection of copper conductor to aluminium terminal • Blank aluminium palm and copper barrel
• Friction welded high purity aluminium and copper rod • Eliminates electrolytic corrosion
• Clearly marked with crimping position

CONDUCTOR DIMENSIONS mm CRIMPING


DESCRIPT.
AREA mm2 A B C D F DIE
BGRV25MB 25 70 23 4.5 24 22 38-92CU
BGRV35MB 35 70 23 4.5 24 22 38-92CU
BGRV50MB 50 78 27 6.0 28 22 38-115CU
BGRV70MB 70 78 27 6.0 28 22 38-115CU
BGRV95MB 95 103 34 9.8 34 38 38-165CU
BGRV120MB 120 103 34 9.8 34 38 38-165CU

30
CONTENTS

UNINSULATED & PREINSULATE TERMINALS SECTION 4

SECTION 4 BI-METAL LUGS & LINKS NON-INSULATED PRE-INSULATED LUGS & LINKS . .31
UNINSULATED RING TERMINAL UTILUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
PRE-INSULATED RING TERMINAL UTILUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
RING TERMINAL SUPERGRIP UTILUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
UNINSULATED FORK UTILUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
SUPERGRIP FORK UTILUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
PRE-INSULATED FORK UTILUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
HIGH TEMPERATURE UTILUG RING TERMINAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
HEAVY DUTY INSULATED RING TERMINAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
BOOTLACE FERRULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
DUAL BOOTLACE FERRULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
UNINSULATED CRIMP PIN CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
PRE-INSULATED PIN CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
SUPERGRIP PIN CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
PRE-INSULATED AND SUPERGRIP CRIMP LINK CABLE CONNECTOR . . . . . . . . . . . . . . .39
CLOSED END PRE-INSULATED CABLE CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
HEAVY DUTY PRE-INSULATED
CRIMP LINK CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
2.8MM Q.C. RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
4.8MM Q.C. RECEPTACLES TO SUIT
0.5MM TABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
6.3MM Q.C. RECEPTACLES TO SUIT
0.8MM TABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
6.3MM Q.C. TABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
6.3MM ADAPTORS Q.C. PIGGY BACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
9.3MM Q.C. RECEPTACLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
LIP BLADE TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
BULLET TERMINAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
BULLET RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
LOOSE PIECE BRASS CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
TK22 ELECTRICAL TERMINAL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

CATALOGUE INDEX INDEX


TERMINALS

UNINSULATED RING TERMINAL UTILUG


• Electro tinned to minimise corrosion
• Serrated barrel provides secure mechanical and electrical connection
• Also available in continuous strip form
• Suitable for small flexible cables

TERMINAL CONDUCTOR STUD DIMENSIONS mm


DESCRIPT. CAT NO. TOOL NO.
SIZE AREA mm2 SIZE A B C E F
UR1.5M1.6 H3110 M1.6 12.5 5.5 0.7 2.5 4.8
UR1.5M3S H3111 M3 12.5 5.5 0.7 3.7 4.8
UR1.5M3M H3116 M3 14.4 6.6 0.7 3.7 4.8
00
UR1.5M3L H3112 M3 15.8 8.0 0.7 3.7 4.8
0.5
UR1.5M4S H3113 M4 14.4 6.6 0.7 4.3 4.8 76A
NO.1
UR1.5M4L H3114 M4 15.8 8.0 0.7 4.3 4.8
TO 16B
UR1.5M5S H3115 22-16AWG M5 15.8 8.0 0.7 5.3 4.8
UR1.5M5L H3117 M5 21.8 11.6 0.7 5.3 4.8 18
1.5
UR1.5M6 H3118 M6 21.8 11.6 0.7 6.4 4.8 63-1
UR1.5M8 H3119 M8 21.8 11.6 0.7 8.4 4.8
UR1.5M10 H3140 M10 25.5 13.6 0.7 10.5 4.8
UR2.5M3S H3120 M3 14.4 6.6 0.8 3.7 4.8
UR2.5M3L H3121 M3 16.8 8.5 0.8 3.7 4.8 00
UR2.5M4S H3122 M4 14.4 6.6 0.8 4.3 4.8
1.5 76A
UR2.5M4L H3123 M4 16.8 8.5 0.8 4.3 4.8
NO.2
UR2.5M5S H3125 M5 16.8 8.5 0.8 5.3 4.8 16B
TO
UR2.5M5L H3126 M5 16.8 9.5 0.8 5.3 4.8
16-14AWG 18
UR2.5M6 H3127 2.5 M6 21.8 12.0 0.8 6.4 4.8
UR2.5M8 H3128 M8 21.8 12.0 0.8 8.4 4.8 63-1
UR2.5M10 H3129 M10 25.5 13.6 0.8 10.5 4.8
UR6M3 H3132 M3 15.7 7.2 1.0 3.7 6.0
UR6M4S H3130 M4 15.7 7.2 1.0 4.3 6.0 00
UR6M4L H3131 M4 19.6 9.5 1.0 4.3 6.0
76A
UR6M5 H3133 2.5 M5 19.6 9.5 1.0 5.3 6.0
UR6M6 H3134 NO.3 M6 22.5 12.0 1.0 6.4 6.0 16B
UR6M8 H3137 TO M8 27.0 15.0 1.0 8.4 6.0
12-10AWG 18
UR6M10 H3138 M10 27.0 15.0 1.0 10.5 6.0
6.0
UR6M12 H3139 M12 31.6 19.2 1.0 13.0 6.0 63-1
UR6M16 H3161 M16 47.6 31.8 0.9 31.8 6.6
124
UR6M18 H3162 M18 47.6 31.8 0.9 31.8 6.6
UR8.5M6 H3183 M6 23.8 12.0 1.2 6.4 8.5
6.0 00
NO.4
UR8.5M10 H3185A TO M10 29.8 15.0 1.2 10.5 8.5 18
10-8AWG
8.5 124
UR8.5M16 H3187A M16 50.0 31.6 1.2 15.0 8.5
UR20M12 H1851B 5AWG 20.0 M12 54.0 31.8 1.8 15.0 15.9
20
UR20M16 H1851 5AWG 20.0 M16 54.0 31.8 1.8 15.0 15.9

32
TERMINALS

PRE-INSULATED
RING TERMINAL UTILUG
• Copper electro tinned to minimise corrosion
• PVC insulation for insulation support

TERMINAL CONDUCTOR STUD DIMENSIONS mm MAX. INSUL.


DESCRIPT. CAT NO. TOOL NO.
SIZE AREA mm2 SIZE A B C E F DIA. mm
RRM1.6 H4110 M1.6 17.5 5.5 0.7 3.2 10.0
RRM3S H4111 M3 17.5 5.5 0.7 3.7 10.0
RRM3M H4116 M3 19.4 6.6 0.7 3.7 10.0
RRM3L H4112 M3 20.8 8.0 0.7 3.7 10.0 76A
NO.1
11C
RRM4S H4113 0.5 M4 19.4 6.6 0.7 4.3 10.0
11B
RRM4L H4114 RED TO M4 20.8 8.0 0.7 4.3 10.0 3.5
63-4B
RRM5S H4115 1.5 M5 20.8 8.0 0.7 5.3 10.0
102
RRM5L H4117 22-16AWG M5 26.8 11.6 0.7 5.3 10.0 120
RRM6 H4118 M6 26.8 11.6 0.7 6.4 10.0
RRM8 H4119 M8 26.8 11.6 0.7 8.4 10.0
4
RRM10 H4140 M10 30.5 13.6 0.7 10.5 10.0
BRM3S H4120 M3 19.4 6.6 0.8 3.7 10.0
BRM3L H4121 M3 21.8 8.5 0.8 3.7 10.0
BRM4M H4124 M4 17.8 6.6 0.8 3.7 10.0 76A
BRM4S H4122 NO.2 1.5 M4 19.4 6.6 0.8 4.3 10.0 12C
BRM4L H4123 M4 21.8 8.5 0.8 4.3 10.0 12B
4.3
BRM5S H4125 BLUE TO M5 21.8 8.5 0.8 5.3 10.0 63-4U
BRM5L H4126 M5 21.8 9.5 0.8 5.3 10.0 102
BRM6 H4127 16-14AWG 2.5 M6 26.8 12.0 0.8 6.4 10.0 120
BRM8 H4128 M8 26.8 12.0 0.8 8.4 10.0
BRM10 H4129 M10 30.5 13.6 0.8 10.5 10.0
YRM3 H4132 M3 22.7 7.2 1.0 3.7 10.0
YRM4S H4130 M4 22.7 7.2 1.0 4.3 10.0
YRM4L H4131 M4 26.6 9.5 1.0 4.3 10.0 76A
NO.3 2.5
YRM5 H4133 M5 26.6 9.5 1.0 5.3 10.0 13B
YRM6 H4134 M6 29.5 12.0 1.0 6.4 10.0 6.1 63-5U
YELLOW TO
YRM8 H4137 M8 34.0 15.0 1.0 8.4 10.0 102
YRM10 H4138 M10 34.0 15.0 1.0 10.5 10.0 120
12-10AWG 6.0
YRM12 H4139 M12 38.6 19.2 1.0 13.0 10.0
YRM18 H4162 M18 54.8 31.8 0.9 31.8 13.5

33
TERMINALS

RING TERMINAL SUPERGRIP UTILUG


• Fitted with a copper ferrule and pre-insulated
for secure insulation support
• Copper electro tinned to minimise corrosion
• Serrated barrel provides secure
mechanical and electrical connection

TERMINAL CONDUCTOR STUD DIMENSIONS mm MAX. INSUL.


DESCRIPT. CAT NO. TOOL NO.
SIZE AREA mm2 SIZE A B C E F DIA. mm
MYRSGM4 H4202 YELLOW 0.2 TO M4 19.0 6.6 0.5 6.6 8.0
2.4 78
MYRSGM5 H4203 26-22AWG 0.5 M5 19.0 8.0 0.5 8.0 8.0
RRSGM1.6 H4210 M1.6 18.0 5.5 0.7 3.2 10.5
RRSGM3S H4211 M3 18.0 5.5 0.7 3.7 10.5
RRSGM3M H4216 M3 19.9 6.6 0.7 3.7 10.5
RRSGM3L H4212 M3 21.3 8.0 0.7 3.7 10.5 11C
NO.1 0.5 11B
RRSGM4S H4213 M4 19.9 6.6 0.7 4.3 10.5
76B
RRSGM4L H4214 M4 21.3 8.0 0.7 4.3 10.5 3.5
RED TO 63-4B
RRSGM5S H4215 M5 21.3 8.0 0.7 5.3 10.5
102
RRSGM5L H4217 22-16AWG 1.5 M5 27.3 11.6 0.7 5.3 10.5 120
RRSGM6 H4218 M6 27.3 11.6 0.7 6.4 10.5
RRSGM8 H4219 M8 27.3 11.6 0.7 8.4 10.5
RRSGM10 H4240 M10 31.0 13.6 0.7 10.5 10.5
BRSGM3S H4220 M3 19.9 6.6 0.8 3.7 10.5
BRSGM3L H4221 M3 22.3 8.5 0.8 3.7 10.5
BRSGM4S H4222 M4 19.9 6.6 0.8 4.3 10.5 12C
NO.2 1.5 12B
BRSGM4L H4223 M4 22.3 8.5 0.8 4.3 10.5
76B
BRSGM5S H4225 M5 22.3 8.5 0.8 5.3 10.5 4.3
BLUE TO 63-4U
BRSGM5L H4226 M5 22.3 9.5 0.8 5.3 10.5
102
BRSGM6 H4227 16-14AWG 2.5 M6 27.3 12.0 0.8 6.4 10.5 120
BRSGM8 H4228 M8 27.3 12.0 0.8 8.4 10.5
BRSGM10 H4229 M10 31.0 13.6 0.8 10.5 10.5
YRSGM3 H4232 M3 23.2 7.2 1.0 3.7 13.5
YRSGM4S H4230 M4 23.2 7.2 1.0 4.3 13.5
YRSGM4L H4231 NO.3 2.5 M4 27.1 9.5 1.0 4.3 13.5 13B
76B
YRSGM5 H4233 M5 27.1 9.5 1.0 5.3 13.5
6.1 63-5U
YRSGM6 H4234 YELLOW TO M6 30.0 12.0 1.0 6.4 13.5
102
YRSGM8 H4237 M8 34.5 15.0 1.0 8.4 13.5 120
12-10AWG 6.0
YRSGM10 H4238 M10 34.5 15.0 1.0 10.5 13.5
YRSGM12 H4239 M12 39.1 19.2 1.0 13.0 13.5

34
TERMINALS

UNINSULATED FORK UTILUG


• Electro tinned to minimise corrosion
• Square sides provide a non-turn capability
• Suits terminal blocks

TERMINAL CONDUCTOR STUD DIMENSIONS mm


DESCRIPT. CAT NO. TOOL NO.
SIZE AREA mm2 SIZE A B C E F
UF1.5M3 H4312 M3 16.0 6.4 0.7 3.7 4.8 00
0.5
UF1.5M4 H4314 NO.1 M4 16.0 7.2 0.7 4.3 4.8 16
TO
UF1.5M5S H4315 12-16AWG M5 16.0 8.1 0.7 5.3 4.8 63-1
1.5
UF1.5M5L H4317 M5 16.0 9.5 0.7 5.3 4.8 76B
UF2.5M3 H4321 M3 16.0 6.0 0.8 3.7 4.8 00
NO.2 1.5
UF2.5M4 H4323 TO M4 16.0 7.2 0.8 4.3 4.8 18, 16
16-14AWG 2.5
UF2.5M5L H4326 M5 16.0 9.3 0.8 5.3 4.8 76B
UF6M3 H4332 M3 17.4 7.2 1.0 3.7 6.0 00
2.5
UF6M4 H4331 NO.3 M4 18.5 9.0 1.0 4.3 6.0 16
TO
UF6M5 H4333 12-10AWG M5 18.5 9.0 1.0 5.3 6.0 63-1
6.0
UF6M6 H4334 M6 24.5 12.0 1.0 6.4 6.0 18,76B,124
4

SUPERGRIP FORK UTILUG


• Electro tinned to minimise corrosion
• Square sides provide a non-turn capability
• Suits terminal blocks

TERMINAL CONDUCTOR STUD DIMENSIONS mm


DESCRIPT. CAT NO. TOOL NO.
SIZE AREA mm2 SIZE A B C E F
RFSGM3 H4512 NO.1 M3 21.5 6.4 0.7 3.7 10.5 76B
0.5
RFSGM4 H4514 M4 21.5 7.2 0.7 4.3 10.5 11C or 11B
22-16AWG TO
RFSGM5S H4515 M5 21.5 8.1 0.7 5.3 10.5 63-4B
RED 1.5
RFSGM5L H4517 M5 21.5 9.5 0.7 5.3 10.5 102, 120
BFSGM3 H4521 NO.2 M3 21.5 5.7 0.8 3.2 10.5 76B
1.5
BFSGM4 H4523 M4 21.5 7.2 0.8 4.3 10.5 12C or 12B
16-14AWG TO
BFSGM5S H4525 M5 21.5 7.9 0.8 5.3 10.5 63-4U
BLUE 2.5
BFSGM5L H4526 M5 21.5 9.3 0.8 5.3 10.5 102, 120
YFSGM3 H4532 NO.3 M3 24.9 7.2 1.0 3.7 13.5 76B
2.5
YFSGM4 H4531 M4 26.0 9.0 1.0 4.3 13.5 13B
12-10AWG TO
YFSGM5 H4533 M5 26.0 9.0 1.0 5.3 13.5 63-5U
YELLOW 6.0
YFSGM6 H4534 M6 32.0 12.0 1.0 6.4 13.5 102, 120

35
TERMINALS

PRE-INSULATED FORK UTILUG


• Copper electro tinned to minimise corrosion
• Square sides provide a non-turn capability

TERMINAL CONDUCTOR STUD DIMENSIONS mm MAX. INSUL.


DESCRIPT. CAT NO. TOOL NO.
SIZE AREA mm2 SIZE A B C E F DIA. mm
RFM3 H4412 M3 21.0 6.4 0.7 3.7 10.0 9A
NO.1 0.5
RFM4 H4414 M4 21.0 7.2 0.7 4.3 10.0 11C OR 11B
RED TO 3.5
RFM5S H4415 M5 21.0 8.1 0.7 5.3 10.0 63-4B
22-16AWG 1.5
RFM5L H4417 M5 21.0 9.5 0.7 5.3 10.0 99, 102, 120
BFM3 H4421 NO.2 M3 21.0 6.0 0.8 3.7 10.0 9A
1.5
BFM4 H4423 M4 21.0 7.2 0.8 4.3 10.0 12C, 12B, 76B
BLUE TO 4.3
BFM5S H4425 M5 21.0 7.9 0.8 5.3 10.0 63-4U
16-14AWG 2.5
BFM5L H4426 M5 21.0 9.3 0.8 5.3 10.0 99, 102, 120
YFM3 H4432 NO.3 M3 25.5 8.3 1.0 3.7 13.0 9A
2.5
YFM4 H4431 M4 25.5 9.0 1.0 4.3 13.0 13B, 76
YELLOW TO 6.1
YFM5 H4433 6.0 M5 25.5 9.0 1.0 5.3 13.0 63-4B
12-10AWG
YFM6 H4434 M6 31.5 12.0 1.0 6.4 13.0 99, 102, 120

HIGH TEMPERATURE
UTILUG RING TERMINAL
• Rated at 2800C
• Nickel plated

TERMINAL CONDUCTOR STUD DIMENSIONS mm MAX. INSUL.


DESCRIPT. CAT NO. TOOL NO.
SIZE AREA mm2 SIZE A B C E F DIA. mm
RHT1.5M5 H3215 NO.1 22-16AWG 0.5 TO 1.5 M5 19.2 7.9 0.7 7.9 9.0 3.6 76B, 16
RHT2.5M4 H3223 M4 22.5 8.7 0.7 8.7 11.1
NO.2 1.5 TO 76B
RHT2.5M5 H3225 M5 22.5 8.7 0.7 8.7 11.1 4.3
16-14AWG 2.5 16
RHT2.5M6 H3227 M6 27.8 12.7 0.7 12.7 11.1
RHT6M5 H3233 NO.3 2.5 TO M5 24.4 9.5 0.9 9.5 12.7 16, 18,
6.1
RHT6M6 H3234 12-10AWG 6.0 M6 29.3 12.7 0.9 12.7 12.7 76B, 124

36
TERMINALS

HEAVY DUTY INSULATED


RING TERMINAL
• Seamless drawn copper tube electro tinned,
black nylon insulator • Palms radiused

TERMINAL CONDUCTOR STUD DIMENSIONS mm MAX. INSUL.


DESCRIPT. CAT NO. TOOL NO.
SIZE AREA mm2 SIZE A B C E F DIA. mm
RHD0.5M5S H2001S M5 26.0 8.6 0.9 11.1 12.7
RHD0.5M5L H2001L 0.5 1/0.80 M5 29.4 8.7 0.9 15.1 12.7 3.5 76B, 60, 28A
RHD0.5M6 H2002 M6 30.0 10.3 0.8 15.1 12.7
RHD2.5M5 H2036 M5 26.2 9.0 1.0 11.9 12.7
2.5 1/0.80 4.3 76B, 60, 28A
RHD2.5M6 H2037 M6 30.9 10.3 0.9 15.1 12.7
RHD4M5S H2003S M5 28.9 8.7 1.5 11.1 14.0
76B, 60,
RHD4M5L H2003L 4.0 1/0.80 M5 32.6 8.7 1.4 14.7 14.0 6.1
28A, 124
RHD4M6 H2004 M6 32.0 10.0 1.2 15.1 14.0
RHD6M6 H2005 6 7/1.04 M6 31.0 10.0 1.2 15.1 13.0 6.8 60, 124
RHD10M6 H2006 10 7/1.35 M6 31.8 11.9 1.8 15.1 13.0 8.3 60, 124 4

BOOTLACE FERRULES
Nominal
CAT DIMENSIONS
Conductor COLOUR CRIMPING TOOL NO.
NO. (mm2) L F D W
BLF05 0.5 12.0 6.0 1.3 2.6 White #112 #125
BLF07 0.75 12.3 6.0 1.5 2.8 Blue #112 #125
BLF1 1.0 12.3 6.0 1.7 3.3 Red #112 #125
BLF2 1.5 14.3 8.0 2.0 3.5 Black #112 #125
BLF3 2.5 15.4 8.0 2.6 4.0 Grey #112 #125
BLF4 4 16.4 9.0 3.2 4.5 Orange #112 #125 #126
BLF6 6 20.5 12.0 3.9 6.0 Green #112 #121 #126
BLF10 10 20.8 12.0 4.9 7.5 Brown #112 #121 #126
BLF16 16 22.2 12.0 6.2 8.7 Ivory #121
BLF25 25 28.0 16.0 7.9 11.0 Black #121
BLF35 35 30.0 16.0 8.7 12.5 Beige #122
BLF50 50 36.0 20.0 10.9 15.0 Olive #122
BLF70 70 37.0 20.0 14.3 16.0 Yellow #38A
BLF95 95 44.0 25.0 15.3 18.5 Red #38A
BLF120 120 47.6 27.0 17.5 20.3 Blue #38A

DUAL BOOTLACE FERRULES


Nominal
CAT DIMENSIONS
Conductor COLOUR CRIMPING TOOL NO.
NO. (mm2) L F D W
BLFT07 0.75 14.7 8.0 2.1 5.5 Grey #112 #125
BLFT1 1.0 15.1 8.0 2.3 5.5 Red #112 #125
BLFT2 1.5 15.5 8.0 2.6 6.4 Black #112 #125
BLFT3 2.5 18.5 10.0 3.3 8.0 Blue #112 #125
BLFT4 4 23.1 12.0 4.2 8.8 Grey #112 #125
BLFT6 6 26.1 14.0 5.3 9.5 Yellow #112 #125

37
TERMINALS

UNINSULATED CRIMP PIN CONNECTOR


• Electro tinned copper to minimise corrosion
• Sizes 1, 2, 3 circular pin • Sizes 4, 5 flat pin

TERMINAL CONDUCTOR DIMENSIONS mm


DESCRIPT. CAT NO. TOOL NO.
SIZE AREA mm2 A B D F
UP1.5 H2271 NO.1 0.5-1.5 15.9 1.6 9.5 5.2 76B, 00, 16B, 21
UP2.5 H2272 NO.2 1.5-2.5 17.4 2.0 10.3 5.5 76B, 00, 16B, 21
UP6 H2273 NO.3 2.5-6.0 20.6 2.8 11.9 6.6 76B, 00, 16B, 21

PRE-INSULATED PIN CONNECTOR


• Electro tinned copper to minimise corrosion
• PVC insulation • Circular pin

TERMINAL CONDUCTOR DIMENSIONS mm MAX. INSUL.


DESCRIPT. CAT NO. TOOL NO.
SIZE AREA mm2 A B D F DIA mm
RP H2276 NO.1 Red 0.5-1.5 21.0 1.6 9.5 10.3 3.3 76B, 11C, 11B, 99, 102, 120
BP H2278 NO.2 Blue 1.5-2.5 23.8 2.0 10.3 11.9 4.3 76B, 12C, 12B, 99, 102, 120
YP H2280 NO.3 Yellow 2.5-6.0 27.5 2.8 11.9 13.5 6.1 76B, 13B, 99, 102, 120

SUPERGRIP PIN CONNECTOR


• Electro tinned copper to minimise corrosion • Circular pin
• Fitted with a copper ferrule and pre-insulated
for secure insulation support

TERMINAL CONDUCTOR DIMENSIONS mm MAX. INSUL.


DESCRIPT. CAT NO. TOOL NO.
SIZE AREA mm2 A B D F DIA mm
MYPSG H3556 NO.O Yellow 0.2-0.5 18.3 1.2 10.0 8.3 2.2 78
RPSG H2286 NO.1 Red 0.5-1.5 21.0 1.6 9.5 10.3 3.5 76B, 11C, 11B, 99, 102, 120
BPSG H2287 NO.2 Blue 1.2-2.5 23.8 2.0 10.3 11.9 4.3 76B, 12C, 12B, 99, 102, 120
YPSG H2288 NO.3 Yellow 2.5-6.0 27.5 2.8 11.9 13.5 6.1 76B, 13B, 99, 102, 120

38
TERMINALS

PRE-INSULATED AND SUPERGRIP


CRIMP LINK CABLE CONNECTOR
• Solid drawn copper tube • Electro tinned to minimise corrosion
• Centre dimple to ensure correct conductor traverse inside link • Vinyl insulation
STYLE 1. Parallel splice conductor area shown is total of two (or more) conductors to be connected parallel.
Ideal for inline joints between uneven sized conductor – vinyl insulation.
STYLE 2. Centre dimple to ensure correct conductor positions – vinyl insulation.
STYLE 3. Supergrip butt splice with translucent insulation (to ensure correct conductor insertion) and depressed
centre to enable use in appropriate ratchet crimp tool without removal of stopper.

STYLE 1. STYLE 3.

STYLE 2.

CONDUCTOR STYLE DIMENSIONS MAX. INSUL.


DESCRIPT. CAT NO. INSULATION TOOL NO.
AREA mm2 A mm DIA. mm
RL H2068 Red 0.5-1.5 1 15.9 3.2 76B, 11C, 11B, 63-4B, 102, 120
BL H2069 Blue 1.5-2.5 1 7.9 4.0 76B, 12C, 12B, 63-4U, 102, 120
YL H2070 Yellow 2.5-6.0 1 20.4 5.5 76B, 13B, 63-5U, 102, 120 4
RLD H2071 Red 0.5-1.5 2 22.2 3.2 76B, 11C, 11B, 63-4B, 102, 120
BLD H2072 Blue 1.5-2.5 2 25.4 4.0 76B, 12C, 12B, 63-4U, 102, 120
YLD H2073 Yellow 2.5-6.0 2 27.0 5.5 76B, 13B, 63-5U, 102, 120
RLSG H3910 Red 0.5-1.5 3 31.0 4.0 76B, 11C, 11B, 63-4B, 102, 120
BLSG H3911 Blue 1.5-2.5 3 31.0 4.6 76B, 12C, 12B, 63-4U, 102, 120
YLSG H3912 Yellow 2.5-6.0 3 41.0 6.2 76B, 13B, 63-5U, 102, 120

CLOSED END PRE-INSULATED


CABLE CONNECTOR
• Electro tinned to minimise corrosion
• Nylon insulation to maximise diaelectric strength

STRANDING I.D. mm DIMENSIONS


DESCRIPT. CAT NO. TOOL NO.
METRIC B A mm
CEC1 H349 2X24/0.20 2.08 15.1 76B, 11A, 11B
CEC2 H2023 2X24/0.20 3.3 21 28A
CEC5 H2026 2X50/0.25 4.5 27 28A
CEC1.5 H2047 2X32/0.20 2.5 15.2 76B, 11C, 11B
CEC2.5 H2048 2X32/0.20 3.7 18 76B, 13B
CEC4 H2050 2X32/0.20 3.35 19.1 76B, 13B
CEC8 H2049 5X32/0.20 5.0 30 76B

39
TERMINALS

HEAVY DUTY PRE-INSULATED


CRIMP LINK CONNECTOR
• Seamless drawn copper tube
• Black nylon insulated
• Centre dimple to help locate the conductor
• Electro tinned to minimise corrosion

CONDUCTOR STRANDING DIMENSIONS MAX. INSUL.


DESCRIPT. CAT NO. TOOL NO.
AREA mm2 METRIC A mm DIA. mm
LHD2.5S H2051 CE2X24/0.2 1/0.80-7/0.67 30.1 4.7 28, 76B
LHD2.5 H2067 CE2X24/0.2 7/0.67 30.1 4.7 28, 76B
LHD4 H2052 CE2X24/0.2 7/0.67-7/0.85 32.3 6.4 28, 76B
LHD6 H2053 CE2X24/0.2 7/1.04 29.0 8.3 28
LHD10 H2054 CE2X24/0.2 7/1.35 29.0 8.3 76B, 13B

2.8mm Q.C. RECEPTACLE


1. ILLUS. LENGTH MAX. INSUL. WIRE
DESCRIPT. CAT NO. MATERIAL THICKNESS FINISH NOTES
NO. A mm DIA. mm SIZE mm2
Brass/ Red to suit
RQCSG2.8/0.8 H3558 1 0.25 ET 17.9 3.2 0.5-1.5
PVC 0.8 Tab
Brass/ Red to suit
RQCSG2.8/0.5 H3564 1 0.25 ET 17.9 3.2 0.5-1.5
PVC 0.5 Tab

1.

4.8mm Q.C. RECEPTACLES to suit 0.5mm tabs


ILLUS. LENGTH MAX. INSUL. WIRE
DESCRIPT. CAT NO. MATERIAL THICKNESS FINISH NOTES
NO. A mm DIA. mm SIZE mm2
2.
RQCSG4.8 H3559 1 Brass/PVC 0.40 ET 18.7 3.2 0.5-1.5 Red
RQCSG4.8F H3563 2 Brass/PVC 0.35 ET 20.0 2.7 0.5-1.5 Red
BQCSG4.8 H3565 1 Brass/PVC 0.40 ET 18.7 4.0 1.5-2.5 Blue
BQCSG4.8F H3566 2 Brass/PVC 0.35 ET 20.0 3.2 1.5-2.5 Blue

40
TERMINALS

1.
6.3mm Q.C. RECEPTACLES to suit 0.8mm tabs
ILLUS. LENGTH MAX. INSUL. WIRE
DESCRIPT. CAT NO. MATERIAL THICKNESS FINISH NOTES
NO. A mm DIA. mm SIZE mm2
2. RQCSG6.3 H2594A 2 Brass/PVC 0.40 ET 20.5 3.5 0.5-1.5 Red
BQCSG6.3 H2595A 2 Brass/PVC 0.40 ET 20.5 4.3 1.5-2.5 Blue
YQCSG6.3 H2596A 2 Brass/PVC 0.40 ET 24.6 4.3 2.5-6.0 Yellow

3. RQCSG6.3L H2594 1 Brass/PVC 0.40 ET 22.2 3.5 0.5-1.5 Red


BQCSG6.3L H2595 1 Brass/PVC 0.40 ET 23.8 4.3 1.5-2.5 Blue
YQCSG6.3L H2596 1 Brass/PVC 0.70 ET 25.4 6.0 2.5-6.0 Yellow
RQCSG6.3F H3560 4 Brass/PVC 0.70 ET 22.0 2.7 0.5-1.5 Red
BQCSG6.3F H3561 4 Brass/PVC 0.70 ET 22.0 3.2 1.5-2.5 Blue
4. YQCSG6.3F H3562 4 Brass/PVC 0.70 ET 25.0 3.8 2.5-6.0 Yellow

6.3mm Q.C. TABS


1. ILLUS. LENGTH MAX. INSUL. WIRE
DESCRIPT. CAT NO. MATERIAL THICKNESS FINISH NOTES
NO. A mm DIA. mm SIZE mm2
RTSG6.3 H2844 1 Brass/PVC 0.80 ET 23.2 3.5 0.5-1.5 Red
BTSG6.3 H2845 1 Brass/PVC 0.85 ET 24.8 4.3 1.5-2.5 Blue
YTSG6.3 H2846 1 Brass/PVC 0.80 ET 26.3 6.0 2.5-6.0 Yellow

1.
6.3mm ADAPTORS Q.C. PIGGY BACK
ILLUS. LENGTH MAX. INSUL. WIRE
DESCRIPT. CAT NO. MATERIAL THICKNESS FINISH NOTES
NO. A mm DIA. mm SIZE mm2
2. RPBSG6.3 H2847A 1 Brass/PVC 0.80 ET 22.2 3.5 0.5-1.5 Red
BPBSG6.3 H2848A 1 Brass/PVC 0.85 ET 22.2 4.3 1.5-2.5 Blue
YPBSG6.3 H2849 2 Brass/PVC 0.80 ET 33.4 6.0 2.5-6.0 Yellow

9.3mm Q.C. RECEPTACLES


1.
ILLUS. LENGTH MAX. INSUL. WIRE
DESCRIPT. CAT NO. MATERIAL THICKNESS FINISH NOTES
NO. A mm DIA. mm SIZE mm2
YQC9.3 H2853A 1 Brass/PVC – ET 29.2 6.2 2.5-6.0 Yellow

41
TERMINALS

LIP BLADE TERMINALS


1.

2. 4.

3. 5.

ILLUS. LENGTH WIDTH MAX. INSUL. WIRE


DESCRIPT. CAT NO. MATERIAL THICKNESS FINISH NOTES
NO. A mm B mm DIA. mm SIZE mm2
RLB H2736 1 Copper 0.7 ET 24.8 2.9 3.5 0.5-1.5 Red
BLB H2737 1 Copper 0.7 ET 26.8 3.0 3.7 1.5-2.5 Blue
RLBSG H2736A 1 Copper 0.8 ET 27.7 3.0 3.5 0.5-1.5 Red
BLBSG H2737A 1 Copper 0.8 ET 27.7 3.0 4.1 1.5-2.5 Blue
YLBSG H2738A 1 Copper 1.0 ET 30.7 3.0 4.1 1.5-2.5 Yellow
Lipless
RLLBSG H3916A 3 Copper 0.7 ET 17.2 3.0 3.5 0.25-1.5
Miniature Blade
Lipless
BLLBSG H3917A 3 Copper 0.7 ET 18.0 2.7 4.3 0.6-3.0
Miniature Blade
Lipless
YLLBSG H3918A 3 Copper 0.9 ET 22.4 2.7 6.3 2.5-6.0
Miniature Blade
RLLBSGL H4107A 4 Copper 0.8 ET 28.5 2.0 3.5 0.5-1.5 Lipless Long Blade
BLLBSGL H4108A 4 Copper 0.8 ET 28.5 2.0 4.3 1.5-2.5 Lipless Long Blade
RLBW H4107 4 Copper 0.8 ET 25.8 4.6 3.5 0.5-1.5 Red
BLBW H4108 4 Copper 0.8 ET 25.8 4.6 4.3 1.5-2.5 Blue
YLBW H4109 4 Copper 0.8 ET 30.3 4.6 6.3 2.5-6.0 Yellow
RLBSGW H4207 5 Copper 0.8 ET 26.4 4.6 3.5 0.5-1.5 Red Supergrip
BLBSGW H4208 5 Copper 0.8 ET 26.4 4.6 4.3 1.5-2.5 Blue Supergrip
YLBSGW H4209 5 Copper 0.8 ET 30.8 4.6 6.3 2.5-6.0 Yellow Supergrip

BULLET TERMINAL

LENGTH LENGTH MAX. INSUL. WIRE


DESCRIPT. CAT NO. MATERIAL FINISH NOTES
A mm B mm DIA. mm SIZE mm2
RBSG H3919 Brass/PVC ET 20.2 4.0 3.5 0.5-1.5 Mates with H3922
BBSG H3920 Brass/PVC ET 20.7 5.0 4.3 1.5-2.5 Mates with H3923

BULLET RECEPTACLE

LENGTH LENGTH MAX. INSUL. WIRE


DESCRIPT. CAT NO. MATERIAL FINISH NOTES
A mm B mm DIA. mm SIZE mm2
RBRSG H3922 Brass/PVC ET 24.0 4.0 2.7 0.5-1.5 Mates with H3919
BBRSG H3923 Brass/PVC ET 25.0 5.0 3.2 1.5-2.5 Mates with H3920

42
TERMINALS

LOOSE PIECE BRASS CONNECTORS

LENGTH MAX. INSUL. WIRE HAND


DESCRIPT. MATERIAL THICKNESS NOTES
A mm DIA. mm SIZE mm2 TOOLS
4
BULLET RECEPTACLES
H2743 Brass 0.45 17 3.3 0.7-2.1 #17, #61 mates with H2782
BULLET TERMINALS
H2782 Brass 0.45 17 3.3 0.75-1.5 #17, #61 mates with H2743
6.3mm Q.C. RECEPTACLES
H1972 Brass 0.45 19.8 2.8 0.7-2.1 #17, #61, #95
H2833B Nick/Silv 0.4 19.6 3.9 1.0-1.5 #17, #61, #95 Piggy Back
LANCED TAB
H2832 Brass 3 0.7-2.1
6.3mm Q.C. RECEPTACLES CRIMP TYPE
H1192 Brass 0.08/.04 19.8 3.7 0.7-2.1 #17, #61, #95
H1192B Nick/Silv 0.8/0.4 19.8 3.7 0.7-2.1 #17, #61, #95
LANCED Q.C. FOR LANCED CONNECTORS
H3555 Brass 0.3 19.8 3.9 0.6-1.5 #17
4.8mm Q.C. RECEPTACLES
H1143 Brass 0.3 15.4 3.3 0.4-1.5 #61, #94 high temp
H2590B Nick/Silv 0.4 15.4 3.3 0.4-1.5 #61, #94 high temp
FLAG TYPE TO SUIT 0.5mm TAB
H1145 Brass 0.4 12.6 3.3 0.4-1.5 #147
FLAG TYPE
H1191B Nick/Silv 0.45 15.1 3.3 0.7-2.1 #14 Housing H2818, H2819
4.8mm FLAG TYPE TO SUIT 0.5mm TAB
H1145B Nick/Silv 0.4 12.6 3.3 0.4-1.0 #147
EYE TERMINAL TO SUIT 5mm STUD
H430 Brass 0.55 21.4 3.9 0.5-2.5 #17, #61 hole, slot, screw 5.3
H430B Brass 0.55 21.4 3.9 0.5-2.5 #17, #61 hole, slot, screw 5.3

43
TERMINALS

TK22 ELECTRICAL TERMINAL KIT

• 1405 mixed supergrip terminals for 240V/415V applications

• Quality ratchet crimping tool (#102) • Tough metal carry case.

CONTENTS:

CAT. NO. DESCRIPTION QTY


H2594A 6.3mm QC Receptacle Red 50
H2595 6.3mm QC Receptacle Blue 100
H2596A 6.3mm QC Receptacle Yellow 50
H2844 6.3mm QC Tab Red 50
H2845 6.3mm QC Tab Blue 100
H2848 6.3mm QC Piggy Back Adaptor 50
H3560 6.3mm QC Receptacle Red 50
H3561 6.3mm QC Receptacle Blue 50
H3562 6.3mm QC Receptacle Yellow 40
H3563 4.8mm QC Receptacle Red 50
H3910 Window Crimp Link Red 50
H3911 Window Crimp Link Blue 50
H3912 Window Crimp Link Yellow 25
H4213 4.3mm Supergrip Ring Terminal Red 100
H4215 5.3mm Supergrip Ring Terminal Red 100
H4218 6.4mm Supergrip Ring Terminal Red 80
H4223 4.3mm Supergrip Ring Terminal Blue 100
H4225 5.3mm Supergrip Ring Terminal Blue 70
H4234 6.4mm Supergrip Ring Terminal Yellow 40
H4523 4.3mm Supergrip Fork Terminal Blue 100
H4514 4.0mm Spade Connector 100
#102 Crimping Tool 1

44
CONTENTS

OVERHEAD SLEEVES AND LUGS SECTION 5

SECTION 5 OVERHEAD CONDUCTOR SLEEVES & LUGS . . . . . . . . . . . . . . . . . .45


NON TENSION SLEEVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
FULL TENSION SLEEVES – TYPE A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
FULL TENSION SLEEVES – TYPE R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
JUMPER SPLICE SLEEVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
TERMINAL LUGS – TYPE AL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
TERMINAL LUGS – TYPE SL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
ELECTRICAL JOINTING COMPOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
CONNECTORS FOR STRANDED COPPER
CONDUCTORS – IMPERIAL & METRIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
#TY SERIES CRIMPING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
#TR SERIES CRIMPING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
#38A HYDRAULIC CRIMPING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

CATALOGUE INDEX INDEX


OVERHEAD SLEEVES & LUGS

NON TENSION SLEEVES


• Tubular aluminium alloy • Pre-packed with jointing compound
• Individually packed in sealed plastic bags
• Suitable for overhead and underground joints
in industrial and commercial installation
• Suitable for AAC, AAAC and ACSR conductors
• Use hexagonal or indent type of crimps
• Centre barrier included

CONDUCTOR LENGTH NOMINAL UC6


CAT NO.
RANGE O.D. mm A mm O.D. VERSA
NT36 6-8 59 16.5 2
NT44 8-10 70 20.6 2
NT50 10-12 84 20.6 3
NT58 12-13.5 111 22.2 3
NT61 13-14.5 111 25.4 3
NT68 14-16 146 25.4 4
NT80 16.5-19.5 146 30.1 5
NT94 20-23.5 155 35 -
NT114 24.5-26.25 185 50 -

Refer Appendix A (Section 10/Page 109) for full list of cables and applicable product and crimp dies.

FULL TENSION SLEEVES – TYPE A


• Tubular aluminium alloy • Pre-packed with jointing compound
• Individually packed in sealed plastic bags
• Use hexagonal or indent type of crimps
• Designed for full tension splices of
overhead transmission lines
• Suits all aluminium conductors (AAC)
• Centre barrier included

CONDUCTOR LENGTH NOMINAL


CAT NO.
RANGE O.D. mm A mm O.D.
FT36A 6-8 165 16.5
FT44A 8-10 165 20.6
FT50A 10-12 203 20.6
FT58A 12-13.5 203 22.2
FT61A 13-14.5 241 25.4
FT68A 14-16 279 25.4
FT80A 16.5-19.5 318 30.1
FT94A 20-21.75 387 35
FT114A 24.5-26.25 710 50

Refer Appendix A (Section 10/Page 109) for full list of cables and applicable product and crimp dies.

46
OVERHEAD SLEEVES & LUGS

FULL TENSION SLEEVES – TYPE R


• Designed for full tension splices of overhead transmission lines
• Suit conventional or smooth body conductors, ACSR, all aluminium and all aluminium alloy conductors
• Centre barrier included • Remove excess grease from steel core of ACSR cables
• Do not use solvent • Conductor range O.D. measurements nominated
have been determined on the basis of high ratio
aluminium/steel conductor configuration
• For high ratio steel/aluminium conductors
refer to Utilux for recommendation

CONDUCTOR LENGTH NOMINAL


CAT NO.
RANGE O.D. mm A mm O.D
FT36R 6-8 344 16.5
FT44R 8-10 379 20.6
FT50R 10-12 470 20.6
FT61R 13-14.5 505 25.4
FT68R 14-16 530 25.4

Refer Appendix A (Section 10/Page 109) for full list of cables and applicable product and crimp dies.

JUMPER SPLICE SLEEVE


• Tubular aluminium alloy fittings • Pre-packed with jointing compound
• Individually packed in sealed plastic bags
• Suitable for overhead non-tension jumpers
in commercial and industrial installations
• Suitable for AAC, AAAC, ACSR and copper conductor
• Use hexagonal or ident type of crimps
• Centre barrier included

CONDUCTOR CRIMPS PER END LENGTH NOMINAL


CAT NO.
RANGE O.D. mm SERIES 5 SERIES 6 A mm O.D.
+JS36R 6-8 4 2 127 16.5
JS44R 8-10 4 2 165 20.6
JS50R 10-12 6 3 165 20.6
+JS58R 12-13.5 8 4 205 22.2
+JS61R 13-14.5 – 4 205 25.4
JS68R 14-16 – 4 205 25.4
JS80R 16.5-19.5 – 4 205 30.1
JS94R 20-23.5 – – 205 35

Refer Appendix A (Section 10/Page 109) for full list of cables and applicable product and crimp dies.
† Made to approved order quantities only.

47
OVERHEAD SLEEVES & LUGS

TERMINAL LUGS – TYPE AL


• Extruded aluminium tube • Pre-filled with jointing compound
• Individually packed in plastic bags
• Designed for compression by hexagonal or indent type tools
• Available also with blank palms
• ACSR, AAAC and AAC conventional and smooth body • Suitable for non tension joints in all industrial,
overhead transmission application • Two hole connection ensure stability

CONDUCTOR IMP. STUD DIMENSIONS mm HOLE


CAT NO.
RANGE O.D. SIZE A B C D CTS.E
AL36 6-8 0.5 129 25 6 82.5 44.5
AL44 8-10 0.5 136.5 27.3 8.8 82.5 44.5
AL50 10-12 0.5 136.5 27.8 7.9 82.5 44.5
AL58 12-13.5 0.5 146.0 31.7 7.5 82.5 44.5
AL61 13-14.5 0.5 149.0 34.9 9.9 82.5 44.5
AL68 14-16 0.5 176.0 34.9 9.9 82.5 44.5
AL80 16.5-19.5 0.5 169.9 41.3 9.9 82.5 44.5
AL94 20-23.5 0.5 176.0 34.9 9.9 82.5 44.5

Refer Appendix A (Section 10/Page 109) for full list of cables and applicable product and crimp dies.

TERMINAL LUGS – TYPE SL


• Extruded aluminium tube • Pre-filled with jointing compound
• Individually packed in plastic bags
• Designed for compression by hexagonal or indent type tools
• Available also with blank palms
• Recommended conductor ACSR, AAAC or AAC – conventional and smooth body
• Suitable for non tension joints in all industrial, overhead transmission applications

CONDUCTOR IMP. STUD DIMENSIONS mm


CAT NO.
RANGE O.D. SIZE A B C D
SL36 6-8 0.5 81.0 22.2 7.4 38.1
SL44 8-10 0.375 90.0 27.0 9.0 38.1
SL50 10-12 0.5 92.1 27.8 7.9 38.1
SL58 12-13.5 0.5 101.6 31.8 7.5 38.1
SL61 13-14.5 0.5 104.8 34.9 9.9 38.1
SL68 14-16 0.5 131.5 34.9 8.4 38.1
SL80 16.5-19.5 0.5 125.4 41.3 9.9 38.1

Refer Appendix A (Section 10/Page 109) for full list of cables and applicable product and crimp dies.
Made to minimum order only

ELECTRICAL JOINTING COMPOUND


Recommended whenever aluminium is part of a connection
• H2397 with zinc particles suspended in a no melt grease penetrates
the oxide film on aluminium surfaces and provides low initial contact resistance
• The compound in the joint seals out air and moisture
preventing oxidation or corrosion and ensures high conductivity

CAT NO. NO. APPLICATION PART COLOUR TUBE SIZE


H2397 4C Conductive compound with zinc particles Zn KD Grey 325g

48
OVERHEAD SLEEVES & LUGS

CONNECTORS FOR STRANDED COPPER CONDUCTORS


– IMPERIAL & METRIC
Connector Material – copper, metal sprayed internally • Superior tensile strength
• Considerable reduction in mass of finished joint
• Elimination of corrosion

IMPERIAL

STRANDING CONNECTOR DIMENSIONS CRIMP GROOVE REC. TOOL CRIMPS PER


CAT NO.
IMPERIAL O.D. mm LENGTH mm SIZE mm TYPE CONNECTOR
TDCS1 7/.044 6.35 38 6.35 #TY 4
TDCS2 7/.048 6.35 38 6.35 #TY 4
TECS1 7/.052 7.94 64 7.94 #TY 8
TECS2 7/.064 7.94 64 7.94 #TY 8
TFCS1 7/.080 9.52 76 9.52 #TR 8
TFCS2 19/.052 9.52 76 9.52 #TR 8
TFCS3 7/.083 9.52 76 9.52 #TR 8
TFCS4 7/.092 9.52 76 9.52 #TR 8
TGCS1 7/.097 12.70 89 12.70 #TR 10
TGCS2 7/.104 12.70 89 12.70 #TR 10
TGCS3 19/.064 12.70 89 12.70 #TR 10
THCS1 7/.136 15.88 127 15.88 #TR 14
THCS2 19/.083 15.88 127 15.88 #TR 14 5
TJCS1 19/.101 22.22 203 19.25 38-193CU 8
TJCS2 37/.072 22.22 203 19.25 38-193CU 8
TKCS1 19/.116 25.40 229 22.00 38-220CU 10
TKCS2 37/.083 25.40 254 22.00 38-220CU 12
TKCS3 37/.093 25.40 254 22.00 38-220CU 12
TMCS1 37/.103 28.57 305 24.74 38-247CU 14

METRIC
STRANDING CONNECTOR DIMENSIONS CRIMP GROOVE REC. TOOL CRIMPS PER
CAT NO.
METRIC O.D. mm LENGTH mm SIZE mm TYPE CONNECTOR
TDCSM1 7/1.00 6.35 38 6.35 #TY 4
TDCSM2 7/1.04 6.35 38 6.35 #TY 4
TDCSM3 7/1.25 6.35 38 6.35 #TY 4
TECSM1 7/1.35 7.94 64 7.94 #TY 8
TECSM2 7/1.70 7.94 64 7.94 #TY 8
TECSM3 7/1.75 7.94 76 7.94 #T7 8
TFCSM1 7/2.14 9.52 76 9.52 #TR 8
TFCSM2 19/1.35 9.52 76 9.52 #TR 8
TGCSM1 7/2.75 12.70 89 12.70 #TR 10
TGCSM2 19/1.53 12.70 89 12.70 #TR 10
TGCSM3 19/1.70 8.50 89 12.70 #TR 10
THCSM1 7/3.50 15.88 127 15.88 #TR 14
THCSM2 19/1.78 15.88 127 15.88 #TR 14
THCSM3 19/2.14 15.88 127 15.88 #TR 14
TJCSM2 19/2.70 22.22 203 – 38-193CU 8

49
OVERHEAD SLEEVES & LUGS

#TY SERIES CRIMPING TOOL


LENGTH 381mm • WEIGHT 1.16kg
Available in various crimp groove size combinations. The complete range is adjustable and robust.
All models are supplied complete with adjusting key and G0-No Go gauge to ensure a perfect crimp every time.

CAT NO. CRIMP GROOVE SIZES mm


#TY476556 4.76 and 5.56
#TY476635 4.76 and 6.35
#TY556635 5.56 and 6.35
#TY635794 6.35 and 7.94

#TR SERIES CRIMPING TOOL


LENGTH 534mm • WEIGHT 2.7kg
This Crimping Tool is available in various crimp groove size combinations. The complete range is adjustable and robust.
All models are supplied complete with adjusting key and Go-No Go guage to ensure a perfect crimp every time.

CAT NO. CRIMP GROOVE SIZES mm


#TR9521270 9.52 and 12.70
#TR794952 7.94 and 9.52
#TR1588 15.88 (single groove)

#38A HYDRAULIC CRIMPING TOOL


LENGTH 580mm • WEIGHT 5.8g
Designed to accept hexagonal, circular and indent dies for appyling compression connectors. The compression head
will rotate through 1800 arc. The body and handles of the tool are neoprene covered to provide mechanical protection.

SLEEVE DIE NO.


#TD 38-44CU
#TE 38-63CU
#TF 38-77CU
#TG 38-104CU
#TH 38-130CU
#TJ 38-193CU
#TK 38-220CU
#TM 38-247CU

50
CONTENTS

BOLTED OVERHEAD CONNECTORS SECTION 6

SECTION 6 BOLTED OVERHEAD CONNECTORS . . . . . . . . . . . . . . . . . . . . . . .51


GENERAL PURPOSE
OVERHEAD LINE TAP CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
DISCONNECT TEE CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
SERVICE CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
LINE STIRRUP CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
ELECTRICAL JOINTING COMPOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
PARALLEL GROOVE CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
BI-METAL PG CLAMPS –
DOUBLE & TRIPLE BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
ALUMINIUM PG CLAMPS – DOUBLE BOLT . . . . . . . . . . . . . . . . . . . . . . . . .55
COPPER PG CLAMPS – SINGLE BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
COPPER PG CLAMPS – DOUBLE BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
SPLIT BOLT CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

CATALOGUE INDEX INDEX


OVERHEAD BOLTED CONNECTORS

GENERAL PURPOSE
OVERHEAD LINE TAP CONNECTOR
• General purpose for bare overhead conductors applications where tap is required to carry full line current
• Combined bolted and compression connection technology
• Special aluminium alloy body for strength and ductility
• Integral belleville washers • Stainless Steel fasteners
• Captive nut • Contact Surfaces pre-coated with Utilux No.3G jointing compound

LINE CONDUCTOR Ø I.D. (XXY)


CAT NO. DESCRIPTION
RANGE (COND. OD)
Bore dimension ø ID
LTGSXXY Line Tap Connector 6-19mm eg. for a bore of 17.5mm, xxy = 175

DISCONNECT TEE CLAMP


• All aluminium • Accepts Aluminium
single hole crimp lugs

CONDUCTOR DIMENSIONS mm BOLT SET


CAT NO.
RANGE O.D. A B C DIA. SCREW
TCDA19 7-19 120.0 75.0 42.0 M10 x 50 M12 X 40

Made to minimum order only

52
OVERHEAD BOLTED CONNECTORS

SERVICE CONNECTOR
• Cast high strength aluminium alloy connector identified with Catalogue No. and cable range
• Available in two configurations
TYPE 1. Tinned split bolt clamp compression crimped into connector body for direct service connection
TYPE 2. Two connectors joined by a customer nominated length of tinned 7/.104 (imperial)
copper conductor (Standard is 254mm) • Available with stainless steel hardware on application

CAT NO. CONDUCTOR RANGE O.D. DIMENSIONS mm BOLT


BT SERIES BT-PP SERIES MAIN TAP A B DIA
*BT2-1 BT2-1PP 15 6 111.1 40.5 M10 X 50
BT2-2 BT2-2PP 15 – 412.8 40.5 M10 X 50

*Accepts 6mm OD cable from 1 to 3 times


BT-PP series contain grease

LINE STIRRUP CLAMP


• Cast high strength aluminium alloy, heat treated • Individually packed in plastic bags and identified with Catalogue
No. and cable range • Tinned stranded copper stirrup is compression crimped into the connector body • Incorporates
anodised aluminium nuts and bolts • Bolts are located in retaining channels to prevent slip during installation
• Features the combination of a parallel groove clamp and a line stirrup
clamp, enabling copper taps to be made at bridging locations.
Application – connection of copper conductors to aluminium mains
• LS-PP Series pre-packed with jointing compound 6
• LS-PPSS Series pre-packed with joining
compound and with Stainless Steel hardware

CAT NO. CONDUCTOR RANGE O.D. DIMENSIONS mm BOLT


LS SERIES LS-PP SERIES LS-PPSS SERIES MAIN AL OR ACSR A B DIA
LS01 LS01PP LS01PPSS 6-19 76.2 146.1 M10 x 50
LS02 LS02PP LS02PPSS 6-19 120.7 146.1 M10 x 50

ELECTRICAL JOINTING COMPOUND


• Seals out air and moisture, therefore minimising oxidation or corrosion
and maximising conductivity
• High melt point grease

CAT NO. NO. APPLICATION PART COLOUR TUBE SIZE


H2398 1 For bolted palm connections No Grit Light Brown
(honey colour) 250g

53
OVERHEAD BOLTED CONNECTORS

PARALLEL GROOVE CONNECTORS


• Cast high strength aluminium alloy, heat treated
• Individually packed in plastic bags and identified with Catalogue No. and cable range
• Anodised aluminium nuts and bolts of sufficient length to allow installation without disassembling connector
• Bolts are located in retaining channels to prevent slip during installation
• Suitable for the following conductors: ACSR, AAC – conventional or smooth body
• Designed specifically for overhead power line applications • PG-PP Series pre-packed with jointing compound
• Stainless steel, electro-tinned or galvanised bolts available for approved minimum order quantities

CAT NO. NO. CONDUCTOR O.D. LENGTH


BOLT
PG SERIES PG-PP SERIES BOLTS MAIN (MAX O.D.) TAP (MIN O.D.) A mm
PG52 PG52PP 1 12 3 37 M10 x 50
PG53 PG53PP 1 19 9 55 M12 x 65
PG66 PG66PP 2 19 9 92 M12 x 65
PG252 PG252PP 2 12 3 72 M10 x 50
PG366 PG366PP 3 19 9 111 M12 x 65

BI-METAL PG CLAMPS – DOUBLE & TRIPLE BOLT


• For aluminium main conductors and copper tap-off conductors • Pressure pad, hex. head screws and nuts
• Clamp body and pressure pad is made of high strength aluminium alloy with compressed bi-metallic sheet for
copper tap-off • Screws: DIN 933 – Steel, greade 8.8 hot-dip galvanised
• Nuts: DIN 934 –Steel, grade 8, hot-dip galvanised

CONDUCTOR CROSS SECTION CONDUCTOR RANGE O.D. LENGTH


CAT NO. BOLT
ALUMINIUM mm2 COPPER mm2 ALUMINIUM mm2 COPPER mm2 A mm
WG3909 16-70 6-50 5.1 to 11.7 2.7 to 9.0 40 2 x M8 x 40
WG3911 12-150 90-95 6.3 to 15.7 4.1 to 12.5 49 2 x M8 x 45
WG3913 35-185 35-185 7.5 to 17.5 7.5 to 17.5 65 2 x M10 x 60
WG3915 95-240 70-185 12.5 to 21.0 10.5 to 17.6 105 3 x M10 x 60

54
OVERHEAD BOLTED CONNECTORS

ALUMINIUM PG CLAMPS – DOUBLE BOLT


• Suitable for aluminium conductors
• Pressure pad, 2 hex, head screws and nuts
Materials: • Clamp body and pressure pad –
high strength aluminium alloy heat treated
• Screws: DIN 933 – steel, grade 8.8 hot-dip galvanised
• Nuts: DIN 934 – Steel grade 8, hot-dip galvanised

CROSS SECTION CONDUCTOR LENGTH


CAT NO. BOLTS
mm2 RANGE O.D. A mm
WG3587 16-35 5.1 to 7.5 41 2 x M7 x 30
WG3588 16-50 5.1 to 9.0 45 2 x M8 x 40
WG3589 16-70 5.1 to 10.5 49 2 x M8 x 45
WG3590 16-95 5.1 to 12.5 55 2 x M8 x 45
WG3591 16-120 5.1 to 14.0 55 2 x M8 x 50
WG3932 25-150 6.3 to 15.7 61 2 x M10 x 50
WG3593 38-185 7.5 to 17.5 65 2 x M10 x 60
WG3594 70-240 10.5 to 20.2 70 2 x M10 x 70

COPPER PG CLAMPS – SINGLE BOLT


• Suitable for copper conductors • Pressure pad, 1 hex, head screw and nut
Materials: • Clamp body and pressure pad – electrolytic copper, E-Cu F30
• Screws: DIN 933 – bronze, having a minimum tensile strength of 60 kp/mm2
• Nuts: DIN 934 – copper, having a minimum tensile strength of 60 kp/mm2

CAT NO.
CROSS SECTION CONDUCTOR LENGTH
BOLTS
6
mm2 RANGE O.D. A mm
WG3005 2.5-16 1.8 to 5.1 16 M5 x 20
WG3006 4-25 2.3 to 6.3 18 M6 x 25
WG3007 6-35 2.7 to 7.5 20 M7x 30
WG3008 6-50 2.7 to 9.0 22 M8 x 35

COPPER PG CLAMPS – DOUBLE BOLT


• Suitable for copper conductors • Pressure pad, 2 hex, head screws and nuts
Materials: • Clamp body and pressure pad – electrolytic copper, E-Cu F30
• Screws: DIN 933 – bronze, having a minimum tensile strength of 60 kp/mm2
• Nuts: DIN 934 – copper, having a minimum tensile strength of 60 kp/mm2

CROSS SECTION CONDUCTOR LENGTH


CAT NO. BOLTS
mm2 RANGE O.D. A mm
WG3025 2.5-16 1.8 to 5.1 24 M5 x 25
WG3026 4-25 2.3 to 6.3 30 M7 x 25
WG3027 6-35 2.7 to 7.5 32 M7 x 30
WG3028 6-50 2.7 to 9.0 35 M8 x 40
WG3029 6-70 2.7 to 10.5 38 M8 x 40
WG3030 16-95 5.1 to 12.5 40 M8 x 40
WG3032 16-150 1.5 to 15.7 50 M10 x 50

55
OVERHEAD BOLTED CONNECTORS

SPLIT BOLT CONNECTORS


• For tapping or joining aerial hard drawn or insulated copper conductors
• Made from hard grade, high conductivity brass
• Captive saddle applies distributed pressure to conductors to ESAA specifications

CAT NO. ESSA MAX CONDUCTOR SIZE SLOT


NATURAL BRASS ELECTRO TINNED TYPE AREA mm2 OVERALL DIA. WIDTH mm
SB22 SB22ET A 16 5.10 5.3
SB24 SB24ET B 35 7.65 8.3
SB25 SB25ET C 70 10.70 10.9
SB26 SB26ET D 95 12.90 12.9
SB28 SB28ET E 185 18.50 18.5

ver you nee


e
d
t
wha

P
L

C
AN HE

56
CONTENTS

TERMINAL BLOCKS SECTION 7

SECTION 7 TERMINAL BLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57


STANDARD RANGE RAIL MOUNTED
TERMINAL BLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
STANDARD RANGE RAIL MOUNTED
TERMINAL BLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
STUD TYPE RAIL MOUNTED
TERMINAL BLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
FIXED SCREW TERMINAL
BLOCKS & ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
QUICK CONNECT TERMINAL BLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
TERMINAL CONFIGURATIONS
& ORDERING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

CATALOGUE INDEX INDEX


TERMINAL BLOCKS

STANDARD RANGE RAIL MOUNTED


TERMINAL BLOCKS
• Manufactured in melamine • Standard colour orange
• Higher current ratings may be obtained at lower ambients

RATED AT CONDUCTOR
CAT. NO.
600V AC SIZE mm2

H2608 25 amps 0.5-10

50mm

12mm
66mm width

CATALOGUE NO. H2608 Metering Block

ACCESSORIES CAT. NO.

Standard End Plate (melamine) H2609

Partition H3865

End Clamp (Nylon) H2232

460mm Mounting Rail H2233

1 metre Mounting Rail H2233A

1 metre Locking Pin H2234A

*Bridging Link H2633


*Bridging Link H2633 supplied in either 2 holes or 10 holes. Specifiy Cat. No. H2633-2 or H2633-10,

Disconnect Plug H2650

Lip Blade Terminal H4207, H4208, H4209

58
TERMINAL BLOCKS

STANDARD RANGE RAIL MOUNTED


TERMINAL BLOCKS
• Manufactured in melamine • Standard colour orange • Higher current ratings may be obtained at lower ambients

RATED AT CONDUCTOR
CAT. NO.
600V AC SIZE mm2

H2238 48 amps 0.5-10

H2238V 65amps 2.5-12

BAR COMBINATIONS

49mm

Standard Vee shaped


Note: Bar Combinations H2238, H2643
Current Bar Current Bar
are available with a “vee” shaped current
bar to accommodate a larger conductor. 12mm
40mm
width
When ordering use Cat No. plus suffix “V”
eg. H2238V, H2643V
CATALOGUE NO. H2238, H2238V Vee shaped current bar

ACCESSORIES CAT. NO.

Standard End Plate (melamine) H2239

Partition H3863

7
End Clamp (Nylon) H2232

460mm Mounting Rail H2233

1 metre Mounting Rail H2233A

1 metre Locking Pin H2234A

Link support and screw H2236M

Bridging Link H2631

Lip Blade Terminal H4207, H4208, H4209

59
TERMINAL BLOCKS

STUD TYPE RAIL MOUNTED


TERMINAL BLOCKS
• A more permanent connection free from loose connections caused by vibration • Being a fixed stud, eye or slotted
terminals can be used on wiring to ensure a more positive connection • Voltage – 500V max. conductor 7/1.70mm copper

RATED AT
CAT. NO.
600V AC

H3820 30 amps

CATALOGUE NO. H3820, Nylon 6/6 1200C, Hardware: Stainless Steel

ACCESSORIES CAT. NO.

End Plate H3821

Partition H3865

Cover (standard length 2m) H3822

Marker Strip H3823

Bridging Link H3824P

1 metre Locking Pin H2234A

460mm Mounting Rail H2233

1 metre Mounting Rail H2233A

Nylon End Clamp H2232

60
TERMINAL BLOCKS

FIXED SCREW TERMINAL BLOCKS & ACCESSORIES

H2502 4 WAY (120 L X 45 W) H2501 6 WAY (120 L X 45 W)


H2511 4 WAY (86 L X 45 W)
H2512 5 WAY (104 L X 45 W)

Links AMP CLEAR COVER


TERMINAL
TYPE COMPLETE WITH RATING AT LINKS POLY. SECURING
BLOCK
600V AC COVERS NUT
H2501N 6 way Stainless Steel 5mm studs, nuts, 80 H2501M
spring & flat washers, slotted H2516 H2508
H2501M slotted link H2517 H2508
Bridging Link H2501EN 6 way Stainless Steel 5mm studs, nuts, 80 H2501L
spring & flat washers, solid H2516 H2508
H2501L solid link H2517 H2508
H2502 4 way Stainless Steel OBA studs, nuts, 80 H2502L
spring washers, solid H2516 H2509
H2502L solid link H2517 H2509
H2502E 4 way Stainless Steel OBA studs, nuts, 80 H2502M H2516 H2509
spring washers, H2502M slotted link slotted H2517 H2509
Cover Securing Nut
H2511N 4 way Stainless Steel 5mm studs, nuts, 80 H2501L
spring washers, H2501L solid link solid - -

H2512N 5 way Stainless Steel 6mm studs, nuts, 80 H2501L


spring washers, H2501L solid link solid - -

Clear Polycarbonate Covers 7

12 WAY TERMINAL STRIP


• Melamine body
• Phosphor bronze wire protector to prevent
clamping screw from pinching the conductor
• Clamping contact is vibration proof
• May be cut to desired length

H2519
LENGTH 133mm

61
TERMINAL BLOCKS

QUICK CONNECT TERMINAL BLOCKS


• Available in 1 to 17 stations (including mounting holes) • QC male outlets to clients specifications
• Mounting holes 4.8mm dia, hole centres are 11.1mm apart • Economical, convenient, safe and simple
• Special blocks can be made to suit individual requirements
• Used by all leading Domestic Appliance Manufacturers
• Manufactured to Australian standards

RATED AT
CAT. NO.
240V AC

TB SERIES 20 amps

TERMINAL CONFIGURATIONS & ORDERING GUIDE


• All parts rated 20 amps screwed connections • Active (A), Neutral (N), Earth (E), engraving available
• Plating is an optional extra • All tabs suit 6.3mm receptacles • Specify terminal style required by using table shown

62
CONTENTS

APPLICATION TOOLING SECTION 8

SECTION 8 APPLICATION TOOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63


ERGONOMIC DESIGN HAND CRIMP TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . . . . .64
ECONOMY RANGE CRIMP TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . . . . .66
PROFESSIONAL RANGE CRIMP TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . . . . .68
HEAVY DUTY HAND OPERATED
HYDRAULIC CRIMP TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
HEAVY DUTY BATTERY OPERATED
HYDRAULIC CRIMP TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
ACCESSORIES FOR BATTERY
POWERED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
HEAVY DUTY HYDRAULIC CRIMPING HEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
HEAVY DUTY HYDRAULIC CRIMPING HEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
HEAVY DUTY HYDRAULIC CRIMPING HEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
HYDRAULIC PUMPS AND CONTROLLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
CABLE CUTTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
BATTERY OPERATED CABLE CUTTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
HYDRAULIC CABLE CUTTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
DATA PRODUCTS TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
CABLE STRIPPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
CRIMPING DIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
12 TONNE DIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
HEXAGONAL CRIMP DIES – COPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
HEXAGONAL CRIMP DIES – ALUMINIUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
INDENT CRIMP DIES – SECTOR ALUMINIUM . . . . . . . . . . . . . . . . . . . . . . . . . . .87
HEXAGONAL CRIMP DIES – HALF HEX (FOR FLEXIBLE CABLES) . . . . . . . . . . .88
HEXAGONAL CRIMP DIES –
C CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
HEXAGONAL CRIMP DIES – STEEL CORES OF ACSR CONDUCTOR . . . . . . . . . .88
HEXAGONAL CRIMP DIES –
INSULATED ABC CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
DIES FOR 5 TONNE TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
DIES FOR 18 TONNE TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
DIES FOR 40 TONNE TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
DIES FOR 40 TONNE TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
HEXAGONAL CRIMP DIES - HALF HEX (FOR FLEXIBLE CABLES) . . . . . . . . . . . .90
#TY SERIES CRIMPING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
#TR SERIES CRIMPING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

CATALOGUE INDEX INDEX


APPLICATION TOOLING

ERGONOMIC DESIGN HAND CRIMP TOOLS


The world’s first truly user friendly crimp tool range, with careful ‘ergonomical’ consideration given to the
shape, weight and balance whilst maintaining optimum mechanical advantage.
Designed to minimise RSI and associated workplace injuries, these award winning tools provide precise and
dependable crimps, without undue discomfort and strain to the user.

CAT NO. DESCRIPTION

#120 Ergonomic design ratchet crimp tool for red, blue and yellow preinsulated
terminals.
RANGE..................... Red, blue and yellow, 0.75 to 6.0mm2
CRIMP TYPE ............ Oval
LENGTH ................... 255mm
WEIGHT ................... 550g

CAT NO. DESCRIPTION

#121 Ergonomic design ratchet crimp tool for boot lace terminals.
Terminals load from the side.
RANGE..................... 10 to 25mm2
CRIMP TYPE ............ D shape
LENGTH ................... 255mm
WEIGHT ................... 550g

CAT NO. DESCRIPTION

#122 Ergonomic design ratchet crimp tool for boot lace terminals.
Terminals load from the side.
RANGE..................... 35 to 50mm2
CRIMP TYPE ............ D shape
LENGTH ................... 255mm
WEIGHT ................... 550g

64
APPLICATION TOOLING

CAT NO. DESCRIPTION

#124 Ergonomic design ratchet crimp tool for uninsulated terminals.

RANGE..................... 4 to 10mm2
CRIMP TYPE ............ Indent
LENGTH ................... 255mm
WEIGHT ................... 550g

CAT NO. DESCRIPTION

#125 Ergonomic design ratchet crimp tool for boot lace terminals.
Terminals load from the front of the tool.
RANGE..................... 0.5 to 6.0mm2
CRIMP TYPE ............ D shape
LENGTH ................... 255mm
WEIGHT ................... 550g

CAT NO. DESCRIPTION

#126 Ergonomic design ratchet crimp tool for boot lace terminals.
Terminals load from the side.
RANGE..................... 4 to 10mm2
CRIMP TYPE ............ D shape
LENGTH ................... 255mm
WEIGHT ................... 550g

8
ALTERNATE AND REPLACEMENT JAWS AVAILABLE UPON REQUEST

atever you
h
w

ne
ed
CA

N
HELP

65
APPLICATION TOOLING

ECONOMY RANGE CRIMP TOOLS


A range of high quality, but economically priced hand crimp tools ideal for the occasional professional user or
serious hobbyist. These easy to use precision engineered tools produce a first class job and offer the user
great value for money.

CAT NO. DESCRIPTION

#76B Non ratchet pliers for pre-insulated and uninsulated terminals.


Includes wire cutting and stripping positions.
RANGE..................... 0.5mm2 to 4.0mm2
CRIMP TYPE ............ Pre-insulated – Oval; Uninsulated – Indent
LENGTH ................... 203mm
WEIGHT ................... 250g

CAT NO. DESCRIPTION

#61 Non ratchet pliers for open barrel, roll in crimp type terminals such as
H1972. Features a built in wire stripper and cutter.
RANGE..................... 0.75mm2 to 2.1mm2
CRIMP TYPE ............ Roll-in for open barrel terminals
LENGTH ................... 210mm
WEIGHT ................... 230g

CAT NO. DESCRIPTION

#147A Non ratchet pliers for micro and flag QC open barrel terminals.
Features a built in wire stripper and cutter.
CRIMP TYPE ............ Roll-in for open barrel terminals
LENGTH ................... 210mm
WEIGHT ................... 230g

CAT NO. DESCRIPTION

#00 General purpose pliers for uninsulated copper lugs and links.
Simple and robust. A must for every tradesman.
RANGE..................... 0.5mm2 to 10.0mm2
CRIMP TYPE ............ Indent
LENGTH ................... 254mm
WEIGHT ................... 450g

CAT NO. DESCRIPTION

#102 Ratchet type tool for pre-insulated and supergrip terminals. The ratchet ensures
a complete crimp every time. A must have tool for every tradesman.
RANGE..................... Red, Blue and Yellow pre-insulated (0.5 to 5.5mm2)
CRIMP TYPE ............ Oval on conductor/Diamond on insulation
LENGTH ................... 230mm
WEIGHT ................... 550g

66
APPLICATION TOOLING

CAT NO. DESCRIPTION

#102M Ratchet type tool for miniature yellow type pre-insulated terminals
(eg. H4200) ..............
RANGE..................... 0.2mm2 to 0.5mm2
CRIMP TYPE ............ Oval
LENGTH ................... 230mm
WEIGHT ................... 230g

CAT NO. DESCRIPTION

#102U Ratchet type tool for uninsulated terminals. The ratchet ensures a
complete crimp every time. A must have tool for every tradesman.
RANGE..................... 0.5 to 8.0mm2
CRIMP TYPE ............ Indent
LENGTH ................... 230mm
WEIGHT ................... 550g

CAT NO. DESCRIPTION

#112 Ratchet type tool for boot lace terminals. The ratchet ensures a complete
crimp every time. A must have tool for every tradesman.
RANGE..................... 0.5mm2 to 10mm2 JAW NO. CABLE (mm2)
CRIMP TYPE ............ U 1 0.5 to 0.75
LENGTH ................... 230mm 2 1.0
3 1.5
WEIGHT ................... 550g 4 2.5
5 4 to 6
6 10

CAT NO. DESCRIPTION

#11C Ratchet type tool for RED (0.5 to 1.5mm2) pre-insulated terminals only,
with terminal locator. Ideal for OEM and production applications. Red
handles match terminal colour, and identify which terminals can be crimped.
CRIMP TYPE ............ Oval on conductor/Diamond on insulation
LENGTH ................... 265mm
WEIGHT ................... 540g

8
CAT NO. DESCRIPTION

#12C Ratchet type tool for BLUE (1.5 to 2.5mm2) pre-insulated terminals only,
with terminal locator. Ideal for OEM and production applications. Blue
handles match terminal colour, and identify which terminals can be crimped.
CRIMP TYPE ............ Oval on conductor/Diamond on insulation
LENGTH ................... 265mm
WEIGHT ................... 540g

CAT NO. DESCRIPTION

#13B Ratchet type tool for YELLOW (2.5 to 6.0mm2) pre-insulated terminals only,
with terminal locator. Ideal for OEM and production applications. Yellow
handles match terminal colour, and identifies which terminals can be crimped.
CRIMP TYPE ............ Oval on conductor/Diamond on insulation
LENGTH ................... 330mm
WEIGHT ................... 970g

67
APPLICATION TOOLING

PROFESSIONAL RANGE CRIMP TOOLS


Built to last, these tools are ideal for the professional or specialist. The precision crafted mechanisms and
uncomp-romised material quality of these tools will ensure years of trouble free operation, and results you can
depend on.

CAT NO. DESCRIPTION

#63 Bench mounted air operated crimp tool with interchangeable crimp jaws
for a range of applications. Includes foot operated controller and
pneumatic hoses. Five interchangable crimp jaws.
RANGE..................... Up to 6mm2 terminals
CRIMP TYPE ............ Depends on jaws selected
INPUT....................... 490kPa air
OUTPUT................... 1.3 tons
WEIGHT ................... 2kg

#4BJAWS/1.............. For RED pre-insulated terminals


Interchangable Jaws #4UJAWS/1 ............. For BLUE pre-insulated terminals
for #63 bench #5UJAWS/1 ............. For YELLOW pre-insulated terminals
mounted #1JAWS/1 ................ For uninsulated lugs and links 1.5 to 6.0mm2
crimper #7JAWS/1 ................ For closed end connectors 0.5 to 6.0mm2
Custom made jaws available on request.

CAT NO. DESCRIPTION

#16B Ratchet type tool for uninsulated copper lugs (CG series).
The long handles require less crimping effort.
RANGE..................... 0.5 to 10mm2
CRIMP TYPE ............ Indent
LENGTH ................... 250mm
WEIGHT ................... 700g

CAT NO. DESCRIPTION

#18 Ratchet type tool for uninsulated copper lugs (CG series).
The long handles require less crimping effort.
RANGE..................... 5 to 16mm2
CRIMP TYPE ............ Indent
LENGTH ................... 330mm
WEIGHT ................... 700g

68
SECTION 8

CAT NO. DESCRIPTION

#28A Ratchet type tool for Utilux closed end connectors.


RANGE..................... 2.5 - 10mm2
CRIMP TYPE ............ Oval
LENGTH ................... 320mm
WEIGHT ................... 600g

CAT NO. DESCRIPTION

#17 Ratchet type tool for crimping open barrel type terminals
RANGE..................... 0.7 to 2.1mm2
CRIMP TYPE ............ Roll in
LENGTH ................... 280mm
WEIGHT ................... 600g

CAT NO. DESCRIPTION

#20 Mechanical crimper for copper lugs and links. Dial adjustable crimp depth
with cable size indicator.
RANGE..................... 16 to 95mm2
CRIMP TYPE ............ Indent, depth adjustable
LENGTH ................... 560mm
WEIGHT ................... 3.2kg

CAT NO. DESCRIPTION

#21 Hand operated, mechanical lever tool for copper lugs and links.
Features built in, selectable crimp die set for a range of lug and link sizes.
RANGE..................... 6mm2 to 50mm2 8
CRIMP TYPE ............ Hexagonal
LENGTH ................... 410mm
WEIGHT ................... 1.4kg

CAT NO. DESCRIPTION

#22 Hand operated, mechanical lever tool for copper lugs and links.
Features built in, selectable crimp die set for a range of lug and link sizes.
RANGE..................... 6mm2 to 120mm2
CRIMP TYPE ............ Hexagonal
LENGTH ................... 670mm
WEIGHT ................... 3.9kg

69
APPLICATION TOOLING

HEAVY DUTY HAND OPERATED


HYDRAULIC CRIMP TOOLS
The precision engineered hydraulic components used in these tools set the standard which others strive to achieve,
and the user benefits from faster crimp times, less handle effort, easier maintenance, longer tool life and more
dependable results.
The two stage pumping mechanism in selected products means the ram advances quickly up to the connector, then
slows as the hydraulic effort is translated into crimping force. Automatic by-pass valves, provide positive feedback to
the user when the tool has reached its rated output, and the crimp is complete.

CAT NO. DESCRIPTION

#111 Compact hydraulic tool featuring ‘flip top’ head ideal for LVABC work and
smaller copper and aluminium connectors. Versatile multi-sized dies
means only a few die sets are required to cover a broad range of
conductor sizes. (Die sets sold separately).
FEATURES ............... Automatic by-pass valve, Spring assisted head latch,
Trigger operated die retractor, Adjustable ram stroke.
RANGE..................... 6mm2 – 150mm2 (LVABC)
6mm2 – 120mm2 (Cu and Al)
OUTPUT................... 5.2 tonne
RAM STROKE.......... 10 to 15mm
DIE SET.................... ‘111’ type dies
LENGTH ................... 370mm
WEIGHT ................... 2 kg (tool only with die set loaded)
PACKAGING ............ Metal carry case, with die compartment.

CAT NO. DESCRIPTION

#38A Robust and built to last, this hydraulic tool sets the standard for other 12t
hydraulic tools. Precision engineered hydraulic components for maximum
reliability and ease of use and maintenance. (Die sets sold separately).
FEATURES ............... Two stage rapid advance pumping action
Automatic pressure bypass, Replaceable bypass
valve, 180 deg swivel head, Fibreglass handles.
RANGE..................... Up to 300mm2
OUTPUT................... 11.3 tonnes
RAM STROKE.......... 25mm
DIE SET.................... ‘38’ type dies
LENGTH ................... 585mm
WEIGHT ................... 6.0kg (tool only with die set loaded)
PACKAGING ............ Heavy duty plastic carry case, with die compartment.

View Parts List

CAT NO. DESCRIPTION

#98 Like the #38A this tool is built to last, and features an extra wide ‘throat’
opening, allowing removal of the tool over cables up to 38mm in overall
diameter. Ideal for straight through cable joints. (Die sets sold separately).
FEATURES ............... Two stage rapid advance pumping action
Automatic pressure bypass, Replaceable bypass
valve, 180 deg swivel head, Fibreglass handles.
RANGE..................... Up to 300mm2
OUTPUT................... 12 tonnes
RAM STROKE.......... 38mm
DIE SET.................... ‘38’ type dies
LENGTH ................... 640mm
WEIGHT ................... 7.7kg (tool only with die set loaded)
PACKAGING ............ Heavy duty plastic carry case, with die compartment.

70 View Parts List


APPLICATION TOOLING

CAT NO. DESCRIPTION

#41A Complete hydraulic crimping tool kit.


Refer individual components for detailed specifications.
KIT INCLUDES......... #P80 – 10.000 psi hand operated hydraulic pump
#41AH – 12t hydraulic crimp head
#HYH2M – 2m hydraulic hose with couplings
Timber carry box
WEIGHT .................. 29kg (complete)
BOX DIM. ................ 740mm(L) x 270mm(W) x 290mm(H)

CAT NO. DESCRIPTION

#42A Complete air/hydraulic crimping tool kit. Requires 400-700kPa compressed


air supply. Refer individual components for detailed specifications.
KIT INCLUDES......... #PA133 – Air operated hydraulic pump
#41AH – 12t hydraulic crimp head
#HYH2M – 2m hydraulic hose with couplings
Timber carry box
WEIGHT ................... 24kg (complete)
BOX DIM. ................ 740mm(L) x 270mm(W) x 290mm(H)

CAT NO. DESCRIPTION 8


#40B The tool kit for large line and cable work. A complete package of
precision engineered components for the most demanding applications.
Refer individual components for detailed specifications.
KIT INCLUDES......... #40BH – 60 tonne compression head
#P80 – 10,000psi hand pump
#HYH2M, – 2m hydraulic hose with couplings
Aluminium compression head stand
Timber carry box
WEIGHT ................... 51kg (complete)
BOX DIM.................. 740mm(L) x 270mm(W) x 290mm(H)

71
APPLICATION TOOLING

HEAVY DUTY BATTERY OPERATED


HYDRAULIC CRIMP TOOLS
The world’s first hydraulic crimping tools powered by rechargeable Ni-Cd batteries. These tools minimise the effort
required by linesmen and cable jointers to apply crimp connectors, resulting in increased productivity and a reduction
in work related strain injuries. Easy and safe to use with no hydraulic hoses or external power supplies required, these
tools are ideal for live line glove and barrier work, or where access to the joint is difficult or restricted.

CAT NO. DESCRIPTION

#111ROBO Self contained heavy duty tool, requiring no external hoses or


attachments. Ideal for LVABC work. (Die sets sold separately).
INCLUDES ............... 2 x BP70R batteries
1 x CH3FC battery charger
Shoulder strap
RANGE..................... 6mm2 – 150mm2 (LVABC)
6mm2 – 120mm2 (Cu and A1)
FEATURES ............... LED battery charge indicator,180 deg swivel head,
Spring assisted latch type H frame head
OUTPUT................... 5 tonnes
RAM STROKE.......... 13mm
DIE SET.................... ‘111’ type dies
WEIGHT ................... 2.8kg
SIZE.......................... 309mm(L) x 305mm(H) x 75mm(W)
PACKAGING ............ All components packed in plastic carry case

CAT NO. DESCRIPTION

#UC6ROBO Dieless multiple indent type tool often used for overhead work.
Emulates ‘versa crimp’ type.
INCLUDES ............... 1 x BP70R battery
1 x CH3FC battery charger
Shoulder strap
RANGE..................... Up to 19/3.75*
FEATURES ............... LED battery charge indicator,180 deg swivel head.
OUTPUT................... 6 tonnes
RAM STROKE.......... 29mm
DIE SET.................... Dies not required
WEIGHT ................... 4.4kg
SIZE.......................... 360mm(L) x 280mm(H) x 70mm(W)
PACKAGING ............ All components packed in plastic carry case
*consult for application suitability

View Parts List

72
APPLICATION TOOLING

CAT NO. DESCRIPTION

#38ROBO Self contained heavy duty tool, requiring no external hoses or


attachments. (Die sets sold separately).
INCLUDES ............... 2 x BP70R batteries
1 x CH3FC battery charger
Shoulder strap
RANGE..................... Up to 300mm2
FEATURES ............... Large handle opening for gloved work,
LED battery charge indicator,
Rapid ram advance,
Rocker switch for ram advance/retract,
350 deg swivel head
OUTPUT................... 11.3 tonnes
RAM STROKE.......... 25mm
DIE SET.................... ‘38’ type dies
LENGTH ................... 435mm(L) x 275mm(H) x 90mm(W)
WEIGHT ................... 7.5kg (tool only with die set loaded)
PACKAGING ............ Plastic carry case contains all components

View Parts List

CAT NO. DESCRIPTION

#98ROBO Self contained heavy duty tool, requiring no external hoses or attachments.
(Die sets sold separately). This tool has the widest jaw opening in its class
(42mm) making removal from large cables easy.
INCLUDES ............... 2 x BP70R batteries
1 x CH3FC battery charger
Shoulder strap 8
FEATURES ............... Extra wide jaw opening (42mm)
Rapid ram advance
Large handle opening for gloved work,
350 deg swivel head
LED battery indicator
Rocker switch for ram advance/retract,
OUTPUT................... 11.3 tonnes
RAM STROKE.......... 42mm
DIE SET.................... ‘38’ type dies
LENGTH ................... 480mm
WEIGHT ................... 8.5kg (tool only with die set loaded)
PACKAGING ............ Plastic carry case contains all components

View Parts List

73
APPLICATION TOOLING

ACCESSORIES FOR BATTERY POWERED TOOLS

CAT NO. DESCRIPTION

BP70E Rechargeable battery pack for all Utilux battery operated tools.
CAPACITY ................ 1.9 ampere hour
CHARGE TIME......... 95min with CH3FC & CH-70DC, 25 min with CH35EMC
OUTPUT VOLTAGE.. 14.4VDC
SIZE.......................... 100mm(L) x 137mm(H) x 70mm((W)
WEIGHT ................... 800g

CAT NO. DESCRIPTION

BP70 E l Intelligent rechargeable battery pack with LED indicator, for all Utilux
battery operated tools. Indicator shows charge and battery life status.
CAPACITY ................ 1.9 ampere hour
CHARGE TIME......... 1 hr with CH3FC & CH-70DC, 25 min with CH35EMC
OUTPUT VOLTAGE.. 14.4VDC
SIZE.......................... 100mm(L) x 137mm(H) x 70mm(W)
WEIGHT ................... 820g

CAT NO. DESCRIPTION

BP250R Extra heavy duty rechargeable battery pack for all Utilux battery operated
tools. Includes waist strap.
CAPACITY ................ 4.0 ampere hour
CHARGE TIME......... 3 hr with CH3FC, 45 min with CH3FR
SIZE.......................... 228mm(L) x 159mm(H) x 40mm((W)
WEIGHT ................... 2.5kg

CAT NO. DESCRIPTION

CH3FC Mains powered standard battery charger for all Utilux battery packs.
1hr charge time for BP70R and BP70I battery packs.
Includes LED charge indicator.
SIZE.......................... 212mm(L) x 95mm(H) x 105mm((W)
WEIGHT ................... 1.9kg

CAT NO. DESCRIPTION

CH3FR Mains powered standard battery QUICK charger for all Utilux battery
packs. 15mins charge time for BP70R and BP70I battery packs.
Includes 4 function LED indicator.
SIZE.......................... 212mm(L) x 95mm(H) x 115mm((W)
WEIGHT ................... 770g

CAT NO. DESCRIPTION

CH-70DC 12V/24V powered battery charger for all Utilux battery packs.
1 hr charge time for BP70R and BP70I battery packs.
Includes LED charge indicator, and vehicle cigarette lighter plug.
SIZE.......................... 200mm(L) x 95mm(H) x 115mm((W)
WEIGHT ................... 700g

74
APPLICATION TOOLING

HEAVY DUTY HYDRAULIC CRIMPING HEADS


A versatile alternative to the self contained hand operated crimpers, these hydraulic crimping heads will attach
to a range of hand operated or electric pumps. Designed and manufactured to the same exacting standards as
the other hydraulic tools in the Utilux range.
All crimp heads are complete with a coupling to suit Utilux hydraulic hoses. Couplings can be changed to suit
other equipment on request.

CAT NO. DESCRIPTION

#111H Spring assisted latch ‘H’ frame head ideal for LVABC work.
Connects to a range of 10,000 psi pumps. Includes coupling.
FEATURES ............... Spring assisted head latch,
Adjustable ram stroke,
Spring assisted ram retraction
RANGE..................... 6mm2 – 150mm2 (LVABC),
6mm2 – 120mm2 (Cu and Al)
INPUT REQUIRED ... 10,000 psi, single acting pump
OIL VOL. REQ’D ...... 18cc
OUTPUT................... 5.2 tonnes
RAM STROKE.......... 10 to 15mm
DIE SET.................... ‘111’ type dies
LENGTH ................... 250mm
WEIGHT ................... 1.6kg (tool only with die set loaded)
PACKAGING ............ Metal carry case, with die compartment

CAT NO. DESCRIPTION

#41AH ‘C’ frame general purpose compression head. Includes coupling.


FEATURES ............... Robust construction,
Spring assisted ram retraction
RANGE..................... Up to 300mm2
INPUT REQUIRED ... 10,000 psi, single acting pump
OIL VOL. REQ’D ...... 42cc
OUTPUT................... 11.3 tonnes
RAM STROKE.......... 25mm
DIE SET.................... ‘38’ type dies
LENGTH ................... 285mm
WEIGHT ................... 3.6kg (tool only with die set loaded) 8
PACKAGING ............ Metal carry case, with die compartment

View Parts List

CAT NO. DESCRIPTION

#98H ‘C’ frame extra wide (38mm) compression head. Includes coupling.
FEATURES ............... Robust construction,
Spring assisted ram retraction
RANGE..................... Up to 300mm2
INPUT REQUIRED ... 10,000 psi, single acting pump
OIL VOL. REQ’D ...... 72cc
OUTPUT................... 12 tonnes
RAM STROKE.......... 38mm
DIE SET.................... ‘38’ type dies
LENGTH ................... 315mm
WEIGHT ................... 5.0kg (tool only with die set loaded)
PACKAGING ............ Metal carry case, with die compartment

View Parts List 75


APPLICATION TOOLING

HEAVY DUTY HYDRAULIC CRIMPING HEADS

CAT NO. DESCRIPTION

#66H ‘U’ frame increased capacity compression head. Includes coupling.


FEATURES ............... Robust construction,
Spring assisted ram retraction,
Carry handle
RANGE..................... Up to 500mm2
INPUT REQUIRED ... 10,000psi, single acting pump
OUTPUT................... 22 tonnes
DIE SET.................... ‘66’ and ‘38’ type dies
WEIGHT ................... 7.8kg (tool only with die set loaded)

CAT NO. DESCRIPTION

#50AH ‘U’ frame increased capacity compression head for up to 630mm2


connectors. Includes coupling.
FEATURES ............... Robust construction,
Spring assisted ram retraction,
Removable top die for easy application to cable,
Light weight,
Can use ‘38’ type dies with #50ADH adaptor
RANGE..................... Up to 630mm2
INPUT REQUIRED ... 10,000psi, single acting pump
OUTPUT................... 18 tonnes
DIE SET.................... ‘50’ type dies, #50ADH ‘38’ die adaptor
LENGTH ................... 240mm
WEIGHT ................... 5.9kg

CAT NO. DESCRIPTION

#40BH ‘U’ frame high capacity compression head. Includes coupling and alloy stand.
FEATURES ............... Robust construction,
Spring assisted ram retraction,
Carry handle, Removable die cap
RANGE..................... Up to 1000mm2
INPUT REQUIRED ... 10,000psi, single acting pump
OIL VOL. REQ’D ...... 703cc
OUTPUT................... 55 tonnes
RAM STROKE.......... 38.5mm
DIE SET.................... ‘40’ type dies, ‘38’ type dies using #40DH die holder
SIZE.......................... 146mm(dia) x 446mm(H), in stand
WEIGHT ................... 22kg (tool only with die set loaded)
PACKAGING ............ Metal carry case

View Parts List

76
APPLICATION TOOLING

HEAVY DUTY HYDRAULIC CRIMPING HEADS

CAT NO. DESCRIPTION

#67H ‘U’ frame 100t capacity compression head. Suitable for transmission line
work. Includes couplings.
FEATURES ............... Robust construction,
Carry handle,
Removable die cap
RANGE..................... Consult
INPUT REQUIRED ... 10,000psi, double acting pump
OIL VOL. REQ’D ...... 314cc
OUTPUT................... 100 tonnes
RAM STROKE.......... 22mm
DIE SET.................... Made to order ‘100’ type dies
SIZE.......................... 195mm(dia) x 360mm(H)
WEIGHT ................... 32kg

View Parts List

CAT NO. DESCRIPTION

#70H ‘U’ frame 200t capacity compression head. Suitable for transmission line
work. Includes couplings.
FEATURES ............... Robust construction,
Carry handles,
Removable die cap
RANGE..................... Consult
INPUT REQUIRED ... 10,000psi, double acting pump 8
OIL VOL. REQ’D ...... 1,134cc
OUTPUT................... 200 tonnes
RAM STROKE.......... 40mm
DIE SET.................... Made to order ‘200’ type dies
SIZE.......................... 270mm(dia) x 415mm(H)
WEIGHT ................... 84kg

77
APPLICATION TOOLING

HYDRAULIC PUMPS AND CONTROLLERS


A range of quality hydraulic pumps and controllers to suit Utilux crimping heads and hydraulic hoses.
Each pump has been selected to offer the optimum in performance and price for crimping applications.
Pumps for special applications or requiring features not listed can be manufactured to order.

CAT NO. DESCRIPTION

#PA133 Complete air/hydraulic crimping tool kit. Requires 400-700kPa compressed


air supply. Refer individual components for detailed specifications.
FEATURES ............... Rugged construction
Swivel coupling
3 position treadle - advance, hold, release
Base mounting slots
WEIGHT ................... 5.4kg (complete)
SIZE.......................... 370mm(L) x 140mm(W) x 145mm(H)

CAT NO. DESCRIPTION

#P80 Hand operated single acting hydraulic pump. Suitable for use with
Model 111H40BH, 41AH Press Head and NO. 66 crimping head.
FEATURES ............... 2 speed mechanism for faster pumping,
Built in oil pressure relief valve,
Large oil capacity,
Operating pressure 70,000kPa (10,000psi)
OIL CAPACITY ......... 2491cc
OIL PORT ................. 3/8” NPTF
OUTPUT................... 10,000psi
HANDLE EFFORT .... 63.5kg (max)
SIZE.......................... 578mm(L) x 95.3mm(W) x 175mm(H)
WEIGHT ................... 12.7kg

CAT NO. DESCRIPTION

#PUJ1200E Mains (240V) powered portable single acting hydraulic pump.


Suitable for use with a wide range of crimping heads and cylinders
requiring 10,000psi supply and large oil volumes.
FEATURES ............... Robust construction, 2 stage pump
3m remote hand operated pendant controller
OIL CAPACITY ......... 2000cc
OIL PORT ................. 3/8” NPTF
MOTOR .................... 0.38kW
OUTPUT................... 10,000psi
SIZE.......................... 240mm(L) x 240mm(W) x 360mm(H)
WEIGHT ................... 10kg

78
APPLICATION TOOLING

CAT NO. DESCRIPTION

#PGM2304R Petrol engine powered 2 stage pump with 3 way, 2 position valve for use
#PGM2404R with a variety of heads, single or double acting.
FEATURES ............... 70,000kPa (10,000psi) oil pressure
Positive type rewind starter
2 & 4 litre reservoir
Quiet efficient muffler
ENGINE.................... 1.8kW
OUTPUT................... 10,000psi
OIL CAPACITY ......... 3800cc
SIZE.......................... 560mm(L) x 440mm(W) x 570mm(H)
WEIGHT ................... 25kg

CAT NO. DESCRIPTION

HYDRAULIC Standard Style: Utilux hydraulic hoses are manufactured from 2 brades of
HOSES high tensile steel reinforced rubber. The rubber is oil and weather resistant.
All hoses are fitted with a male quick coupler at one end for connection to
the the crimp head, and a 3/8” male NPTF fitting on the other for connection
to the pump.
DIAMETER ............... 9.5 (nom) inside
OPERATING PRESS. 10,000psi
BURST PRESSURE . 20,000psi
#HYH2M................... 2m long hose
#HYH4M................... 4m long hose
#HYH6M................... 6m long hose
Non Conductive Style: Non conductive sheathed hydraulic hoses are also
available for applications requiring electrical isolation of the hose. Orange
coloured sheath for easy identification.
DIAMETER ............... 6.4 (nom) inside
OPERATING PRESS. 10,000psi
BURST PRESSURE . 40,000psi
LEAKAGE................. Less than 50 micro amps
#HYH2MNC ............. 2m long hose
#HYH4MNC ............. 4m long hose
#HYH6MNC ............. 6m long hose

CAT NO. DESCRIPTION

HOSE All Utilux hydraulic crimp tools (where required) are fitted with a female
COUPLINGS hydraulic quick coupler, suitable for connection to Utilux hydraulic hoses.
All couplings include a plastic dust cap.
MALE COUPLING ... #MC38
FEMALE COUPLING #FC38
COUPLING SPECIFICATIONS:
THREAD ................... 3/8” NPT
MAX FLOW ............. 40 litres/min
MAX PRESSURE..... 10,000psi

79
APPLICATION TOOLING

CABLE CUTTERS
A range of simple but robust cable cutters for a variety of applications.

CAT NO. DESCRIPTION

#110 Small single hand operated parrot beak style cutter, ideal for general
applications. Precision blades make this tool ideal for cutting flexible
copper cables.
LENGTH .................... 240mm
WEIGHT .................... 460g

CAT NO. DESCRIPTION

#108 Gear driven large capacity ratchet cable cutter, with rapid blade advance.
robust forged construction cuts up to 400mm2 single core copper cable.
Not suitable for steel.
FEATURES................ Rubber handle grips,
Single hand operation,
Emergency release mechanism,
Blade reversing lever
LENGTH .................... 260mm
WEIGHT .................... 1.1kg

View Parts List

CAT NO. DESCRIPTION

#109 Smaller version of #108 cutter, for cables up to 300mm2.


LENGTH .................... 230mm
WEIGHT .................... 520g

CAT NO. DESCRIPTION

#140 Parrot beak style cable cutter for copper and aluminium conductors up to
240mm2. Replacement blades available.
LENGTH .................... 610mm
WEIGHT .................... 1.8g

CAT NO. DESCRIPTION

#141 Parrot beak style cable cutter for copper and aluminium conductors up to
500mm2. Replacement blades available.
LENGTH .................... 805mm
WEIGHT .................... 2.8g

80
APPLICATION TOOLING

BATTERY OPERATED CABLE CUTTERS


A range of simple but robust cable cutters for a variety of applications.

CAT NO. DESCRIPTION

#REC-50U Portable gear driven cable cutter ideal for many applications. Specially
designed to cut the toughest copper and aluminium cables in a limited
amount of space.
INCLUDES ............... Cutter unit
1 x BP70R battery unit
1 x CH3FC battery charger
FEATURES................ Eliminates possible RSI,
Rocker switch control (fwd and reverse),
Cuts clean with minimal distortion,
Built in overload protection,
Up to 100 cuts from single battery charge
RANGE...................... Up to 50mm OD non-ferrous cables
SIZE ........................... 105mm(L) x 375mm(H) x 115mm(W)
WEIGHT .................... 2.0kg
PACKAGING ............. Metal carry case
View Parts List

CAT NO. DESCRIPTION

#S20AROBO Battery powered hydraulic cutter (refer #CCS20A for application and
cutting range).
INCLUDES ............... Cutter unit
1 x BP70R battery unit
1 x CH3FC battery charger,
Shoulder strap
FEATURES................ Eliminates possible RSI,
Flip top latched head
Head rotates through 350 deg,
Built in overload protection,
RAM STROKE .......... 20mm
OUTPUT.................... 6 tonnes
SIZE ........................... 280mm(L) x 240mm(H) x 75mm(W)
WEIGHT .................... 3.2kg
PACKAGING ............. Durable plastic carry case
8

CAT NO. DESCRIPTION

#S440ROBO Battery powered hydraulic cutter (design for ACSR Cables.).


INCLUDES ............... Cutter unit
1 x BP70EI battery unit
1 x CH35EMC battery charger,
Shoulder strap
FEATURES................ Eliminates possible RSI,
Flip top latched head
Head rotates through 350 deg,
Built in overload protection,
RAM STROKE .......... 40mm
OUTPUT.................... 7 tonnes
SIZE ........................... 440mm(L) x 260mm(H) x 78mm(W)
WEIGHT .................... 6.0kg
PACKAGING ............. Durable plastic carry case

81
APPLICATION TOOLING

HYDRAULIC CABLE CUTTERS


Quality hydraulic cable cutters for the most demanding power cable cutting jobs.
The hydraulic cutters in this range are also suitable for cutting such things as guy wires,
steel bar, earth rods and steel reinforced overhead conductor. Consult the application selection chart for details.
Spare and replacement blades are available.
THESE TOOLS ARE NOT SUITABLE FOR CUTTING HIGH TENSILE STEEL OR PIANO WIRE.

SPECIFICATION CHART

Cat No. Style Oil Vol Output Pumping Head Length Weight
Required (cc) (tonnes) Stages Rotation (deg) (mm) (kg)
#CCS20A Hand Operated - 4 1 180 390 2.8
#CCSP20A Head only 18 4 - - 240 2.1
#CCS32 Hand Operated - 20 1 180 675 9.3
#CCSP32 Head only 135 20 - - 300 10.0
#CCS40A Hand Operated - 6 2 180 580 5.7
#CCSP40A Head only 48 8 - - 340 4.0
#CCS55 Hand Operated - 12 1 180 610 7.9
#CCSP55 Head only 120 12 - - 415 9.0
#CCS75 Hand Operated - 2.5 1 360 645 6.3
#CCS85 Hand Operated - 3 2 180 690 8.7
#CCSP85 Head Only 65 3 - - 460 7.2
#CCSP100 Head only 140 7.5 - - 590 13.2

HYDRAULIC CABLE CUTTERS • APPLICATION SELECTION CHART


Cutting Capacity – Maximum diameter (mm)
NOTE: These tools are not suitable for cutting high tensile steel or piano wire
Soft steel bar
solid sector

Reinforcing
(Telephone)
Cu strands

aluminium
Al strands

Wire rope

Wire rope

Wire rope

Guy wire

Guy wire
3/4 Core

6 x 12

6 x 19

1 x 19
ACSR
Cable

6x7

1x7
CCP

rod

Cat No.

#CCS20A 20 20 - - 16 20 20 16 13 21 15 16
#CCSP20A 20 20 - - 16 20 20 16 13 21 15 16
#CCS32 32 32 - 30 32 32 32 25 25 32 32 32
#CCSP32 32 32 - 30 32 32 32 25 25 32 32 32
#CCS40A 41 41 - 35 22 25 25 20 16 38 15 20
#CCSP40A 41 41 - 35 22 25 25 20 16 38 15 20
#CCS55 55 55 - 50 25 30 30 22 19 50 15 20
#CCSP55 55 55 - 50 25 30 30 22 19 50 15 20
#CCS75 23 29 75 - - - - - - - - -
#CCS85 28 38 85 - - - - - - - - -
#CCSP85 28 38 85 - - - - - - - - -
#CCSP100 42 46 100 - - - - - - - - -

82
APPLICATION TOOLING

View Parts List

#CCS20A #CCSP20A

#CCS32 #CCSP32
View Parts List

#CCS40A #CCSP40A

View Parts List

#CCS55 #CCSP55

View Parts List


8

#CCS75 #CCSP100

#CCS85 #CCSP85

83
APPLICATION TOOLING

DATA PRODUCTS TOOLS


Quality range of tools with the precision, and repeatability demanded by the application of Data Connectors.

CAT NO. DESCRIPTION

#81 Professional 3 in 1 modular tool. Three individual dies allow termination


of 4, 6 and 8 position modular plugs. Handle incorporates cutter and stripper.
FEATURES................ Ratchet operation
Equal distribution of pressure to all contacts
APPLICATION........... 4P / 6P / 8P
LENGTH .................... 210mm
WEIGHT .................... 530g

CAT NO. DESCRIPTION

#142 MRC hand tool, Specifically designed to crimp Utilux moisture resistant
connectors.
FEATURES................ TELSTRA APPROVED (approval No. #S114/165)
LENGTH .................... 180mm
WEIGHT .................... 230g

CAT NO. DESCRIPTION

#88 Professional 3 in 1 modular tool kit comprising:


Foam lined carry case
#81 modular tool
20pcs 8P8C type modular plug
30pcs 6P6C type modular plug
40pcs 4P4C type modular plug
SIZE ........................... 265mm(L) x 235mm(W) x 50mm(H)
WEIGHT .................... 960g

84
APPLICATION TOOLING

CABLE STRIPPERS
Safe and easy to use, this innovative range of tools is the ideal solution to a variety of
cable stripping applications.

CAT NO. DESCRIPTION

#89 This easy to use handtool has been developed for stripping insulation
from electrical cable. Benefits include alloy steel jaws for stripping wire
from 10-26 AWG. Crimps terminals neat and tight. Specially designed
light pressure handles. Wire cutter incorporated.
RANGE..................... 0.13-6mm2
LENGTH ................... 210mm
WEIGHT ................... 300g

CAT NO. DESCRIPTION

#153 Self adjusting strip and cut tool, with sophisticated ‘closed loop’ cam
mechanism which reduces hand effort and minimises operator fatigue.
FEATURES ............... Laminated stripping blade avoids damage to fine
conductors, Direct driven cutter for powerful but
controlled cutting, Fully automatic, no adjustments
required for different cable sizes, Repeatable strip lengths,
No exposed cutting blades, Smooth profile handles
RANGE..................... 0.08 to 6.0mm2 (stripping)
6.0mm2 (max) stranded, 4.0mm2 (max) solid
SIZE.......................... 205mm(L) x 19mm(W) x 105mm(H)
WEIGHT ................... 200g

CAT NO. DESCRIPTION

#151 Self adjusting wire stripper and cutter specially designed for flexible cables.
FEATURES................ Compact design, pocket sized,
Unique design ensures no damage to conductors,
Precise rotary action, Integral guillotine wire cutter
Safe, no exposed blades, Strips inner & outer insulation
RANGE...................... Up to 9mm dia cables (stripping) 8
Flexible cables up to 1.5mm2 (cutting)
SIZE ........................... 90mm(L) x 18mm(W) x 38mm(H)
WEIGHT .................... 35g

CAT NO. DESCRIPTION

#154 Rotary action power cable stripper for all insulation types
(PVC, PE, rubber etc). Two sizes available, 29mm and 40mm.
FEATURES ............... Triple Action Strip, Easy to achieve ‘window’ strips,
Unique blade profile for difficult insulation such as
rubber, Replaceable blades
RANGE..................... – 4.5mm
– 19 to 40mm diameter
TRIPLE ACTION LENGTH ................... – 138mm, 153mm (max)
SPIRAL CUT WEIGHT ................... – 100g

85
APPLICATION TOOLING

CRIMPING DIES
Utilux crimping dies for aluminium and copper connectors are precision engineered from EN26 high tensile steel,
oil hardened to 50-52 Rockwell C, ensuring long life and minimal die wear. Each hexagon die set is engraved with
“Utilux” on one of the die faces, and the die part number on the other, leaving an indent on the crimp for easy
inspection and verification.
THE RANGE OF DIES INCLUDES:
• Hexagonal die sets for precision crimping of copper and aluminium connectors
• Nest and indent die sets for special aluminium applications
• Special ‘steel’ dies for crimping steel sleeves
The selection of the die type required depends on the connector to be crimped, and the tool to be used.
Special size dies made to order.

‘38’ SERIES DIE SETS


Suitable for all ‘12 tonne’ hydraulic crimp tools
in the Utilux range, as well as th #66H tool.

Hexagon Die Set Flat Die Indent Die Nest Die

‘40’ SERIES DIE SETS


Suitable for the #40B tool, the #40BH tool and their variants.
Hexagon Die Set

‘50’ SERIES DIE SETS


Suitable for the #50AH tool only
Hexagon Die Set

‘66’ SERIES DIE SETS


Suitable for the #66H tool only

‘111’ SERIES DIE SETS


Suitable for the #111, #111H and #111ROBO tools
Mult-faced Hexagon Die Set

‘67’ AND ‘70’ SERIES DIE SETS


Specially manufactured to order for the #67H and #70H compression heads

DIE HOLDERS
Special die holders are available that allow the use of ‘38’ series dies in the #40B and #50A tools.

#40DH for use the #40B and #40BH tools #50ADH for use the the #50AH tool

86
APPLICATION TOOLING

12 TONNE DIES
HEXAGONAL CRIMP DIES – Copper

COPPER CONDUCTOR COPPER DIE


PRECISION BUDGET
SIZE (mm2) A/F (mm)
6 38-44CU CDC6 4.4
10 38-57CU CDC10 5.7
16 38-63CU CDC16 6.3
20 38-70CU CDC20 7.0
25 38-77CU CDC25 7.7
35 38-92CU CDC35 9.2
50 38-104CU CDC50 10.4
70 38-115CU CDC70 11.5
95 38-142CU CDC95 14.2
120 38-165CU CDC120 16.5
150 38-183CU CDC150 18.3
185 38-200CU CDC185 20.0
240 38-231CU CDC240 23.1
300 38-260CU CDC300 26.0

HEXAGONAL CRIMP DIES – Aluminium

ALUMINIUM CONDUCTOR ALUMINIUM DIE


PRECISION BUDGET
SIZE (mm2) A/F (mm)
6 - 35 38-90AL CDA6/35 9.0
50 - 70 38-132AL CDA50/70 13.2
95 - 120 38-173AL CDA95/120 17.3
150 - 185 38-220AL CDA150/185 22.0
240 - 300 38-284AL CDA240/300 28.4

8
INDENT CRIMP DIES – Sector Aluminium

ALUMINIUM CONDUCTOR 3 CORE 4 CORE


SIZE (mm2) NEST DIE INDENTOR NEST DIE INDENTOR
70 #12NEST #14INDENT #14NEST #14INDENT
95 #12NEST #15INDENT #14NEST #15INDENT
120 #12NEST #16INDENT #14NEST #16INDENT
150 #12NEST #17INDENT #15NEST #17INDENT
185 #12NEST #18INDENT #15NEST #18INDENT
240 #12NEST #19INDENT #15NEST #19INDENT
300 #12NEST #20INDENT #15NEST #20INDENT

87
APPLICATION TOOLING

12 TONNE DIES
HEXAGONAL CRIMP DIES – Half Hex (for flexible cables)

MULTI STRANDED
DIE SET HEX DIE FLAT DIE
CABLE (mm2)
16 38-98HHEX17 38-98CU 38-FLAT17
25 38-122HHEX17 38-122CU 38-FLAT17
35 38-130HHEX17 38-130CU 38-FLAT17
50 38-153HHEX17 38-153CU 38-FLAT17
70 38-183HHEX14 38-183CU 38-FLAT14
95 38-220HHEX14 38-220CU 38-FLAT14
120 38-245HHEX14 38-245CU 38-FLAT14

Note: Flat dies are available individually

HEXAGONAL CRIMP DIES – C Connectors

CABLE RANGE CABLES RANGE


DIE SET DIE SET
(mm2) (mm2)
14 - 20 38-T020 99 - 122 38-T122
21 - 26 38-T026 123 - 154 38-T154
27 - 44 38-T044 155 - 190 38-T190
45 - 60 38-T060 191 - 240 38-T240
61 - 76 38-T076 241 - 288 38-T288
77 - 98 38-T098 289 - 365 38-T365

HEXAGONAL CRIMP DIES – Steel cores of ACSR Conductor

DIE SET DIE A/F (mm) DIE SET DIE A/F (mm)

38-74ST13 7.4 38-95ST 9.5


38-76ST 7.6 38-95ST13 9.5
38-80ST 8.0 38-130ST7 13.0

HEXAGONAL CRIMP DIES – Insulated ABC Connectors

ABC CABLE DIE SET DIE A/F (mm)

6 - 35 38-140AL9 9.5
25 - 95 38-173AL9 17.3
95 - 150 38-215AL9 21.5

88
APPLICATION TOOLING

DIES FOR 5 TONNE TOOL

CONDUCTOR SIZE (mm2) HEX DIE A/F (mm2)

10 5.7
111-5763CU
16 6.3
25 7.7
111-7792CU
35 9.2
Copper
50 10.4
111-
70 11.5
95 14.2
111-
120 16.5
6, 10, 16, 25, 35 9.0
Aluminium 50, 70 111-ALSPEC 13.2
95, 120 17.3
MFPB Sleeves 14.0
111-
ABC 25 - 95 17.3
95 - 150 111-215AL 21.5

DIES FOR 18 TONNE TOOL

CONDUCTOR SIZE (mm2) HEX DIE A/F (mm2)

400 50A-281CU 28
Copper 500 50A-310CU 31
630 50A-370CU 37
400
Aluminium 50A-390AL 39
500

DIES FOR 60 TONNE TOOL

CONDUCTOR SIZE (mm2) HEX DIE A/F (mm2) 8


70 40-130CU 13.0
95 40-142CU 14.2
120 40-165CU 16.5
150 40-185CU 18.5
185 40-200CU 20.0
240 40-231CU 23.1
Copper
300 40-260CU 26.0
400 40-281CU 28.1
500 40-310CU 31.0
630 40-370CU 37.0
800 40-432CU 43.2
1000 40-480CU 48.0
95, 120 40-172AL 17.2
150, 185 40-220AL 22.0
Aluminium 240, 300 40-283AL 28.3
400, 500 40-390AL 39.0
630 40-432AL 43.2

89
APPLICATION TOOLING

DIES FOR 60 TONNE TOOL


HEXAGONAL CRIMP DIES – Steel Cores of ACSR Conductor

DIE SET DIE A/F (mm) DIE SET DIE A/F (mm)

40-068ST 6.8 40-170ST 17.0


40-95ST 9.5 40-190ST 19.0
40-95ST19 9.5 40-200ST19 20.0
40-140ST19 14.0 40-250ST 25.0
40-160ST 16.0 40-260ST 26.0

#TY SERIES CRIMPING TOOL


LENGTH 381mm • WEIGHT 1.16kg
Available in various crimp groove size combinations. The complete range is adjustable and robust.
All models are supplied complete with adjusting key and G0-No Go gauge to ensure a perfect crimp every time.

CAT NO. CRIMP GROOVE SIZES mm


#TY476556 4.76 and 5.56
#TY476635 4.76 and 6.35
#TY556635 5.56 and 6.35
#TY635794 6.35 and 7.94
#TY556794 5.56 and 7.94

#TR SERIES CRIMPING TOOL


LENGTH 534mm • WEIGHT 2.7kg
This Crimping Tool is available in various crimp groove size combinations. The complete range is adjustable and robust.
All models are supplied complete with adjusting key and Go-No Go guage to ensure a perfect crimp every time.

CAT NO. CRIMP GROOVE SIZES mm


#TR9521270 9.52 and 12.70
#TR794952 7.94 and 9.52
#TR1588 15.88 (single groove)

90
CONTENTS

CABLE MANAGEMENT SECTION 9

SECTION 9 CABLE MANAGEMENT AND


ASSOCIATED PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
PIN CLIPS H335B SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
COPPER EARTH RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
EARTH CLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
EARTHING STRAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
CABLE HOLDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
CONDUIT BENDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
BATTERY BOOSTER, ALLIGATOR AND
TEST CLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
BATTERY BOOSTER CLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
ALLIGATOR CLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
TEST CLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
ALLIGATOR AND TEST CLIP INSULATORS . . . . . . . . . . . . . . . . . . . . . . . . . .95
STAINLESS STEEL BAND CLAMP & BUCKLES . . . . . . . . . . . . . . . . . . . . . . .96
SHEATHED BAND CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
#46 BAND CLAMP TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
NYLON BAND CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
#117 NYLON BAND FITTING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
UTI-TIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
UTI-TIE INSTALLATION TOOL #101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
UTI-TIE INSTALLATION TOOL #TGO9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
UTI-TIE INSTALLATION TOOL #69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
STAINLESS STEEL CABLE TIE TENSIONER #116 . . . . . . . . . . . . . . . . . . . . .91
NYLON HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

CATALOGUE INDEX INDEX


CABLE MANAGEMENT

PIN CLIPS
• Manufactured from soft brass, natural finish
• No sharp edges
• Has 12.6mm hardened nail fixed in the pin clip
and recessed
• Strips of six for convenient application
• Pin clips are clearly branded and marked with
the size number for identification
• H335D brass electro tinned with brass electro
tinned pin for use in equatorial
areas and marine applications

CAT. NO.
MATERIAL SIZE LENGTH mm
PLAIN PLATED
H335B#1 H335D#1 Brass with hardened nail 1 38
H335B#2 H335D#2 Brass with hardened nail 2 44
H335B#3 H335D#3 Brass with hardened nail 3 51
H335B#4 H335D#4 Brass with hardened nail 4 57
H335B#5 – Brass with hardened nail 5 64

COPPER EARTH RODS

ROD NOMINAL
CAT. NO. DESCRIPTION LENGTH m
DIA mm
CUP1314WC Domestic – pointed, with clip 13 1.4
CUP1318WC Domestic – pointed, with clip 13 1.8

EARTH CLIPS

CAT. NO. MATERIAL TO SUIT EARTHROD DIA.


SIZE mm
H303A#1 Brass 13
H303A#2 Brass 16
H303A#3 Brass 19
H303A#4 Brass 25

EARTHING STRAPS

CAT. NO. MATERIAL LENGTH mm


H803A Brass 101

92
CABLE MANAGEMENT

CABLE HOLDERS

FUNCTION: For securing electrical cable from a diameter of 30mm up to 100mm, to a power pole or beam.

DESIGN FEATURES: The design of the cable holder allows for a variety of sizes of cable, due to the variable

adjustment and locking points.

The unique design features of the cable holder are the:

• Dual support legs which allow for dual fixing to a pole

• Optonal fixing methods, either using a bolt or bandclamp strapping

MATERIAL: The clamp body is made from mild steel, which has been blanked and formed, then hot-dip galvanised.

• The strap is made from 304 grade stainless steel.

• The pin is zinc diecast.

MARKETS: The clamp has applications in power

authorities, mining, railways, building and construction.

ADDITIONAL INFORMATION: A variation to this product is

a vertical version, where the fixing points run parallel to

the stainless steel strap.

CBH30-100

CBH30-100V

CAT NO. CABLE DESCRIPTION 9


CBH30-100 30-100mm dia Pole mounted clamp - Horizontal
CBH30-100V 30-100mm dia Pole mounted clamp - Vertical

93
CABLE MANAGEMENT

CONDUIT BENDERS

The range of Utilux conduit benders are designed for controlled bending of steel conduit and copper pipe without

crushing or local deformation occuring.

There are two sizes of bender available, 16mm – 20mm and 25mm. Each bender is made up from two parts, a high

strength aluminium head and a galvanised steel handle.

PART NO. CONDUIT SIZE DESCRIPTION


AC2071 16-20mm Head
AC2071H 16-20mm Handle
AC2081 25mm Head
AC2071H 25mm Handle

ver you nee


e
d
t
wha

P
L

C
AN HE

94
CABLE MANAGEMENT

BATTERY BOOSTER, ALLIGATOR AND TEST CLIPS

BATTERY BOOSTER CLIPS


• All battery clips supplied in equal quantities of positive and negative
• All clips supplied with handles
• H811 has a copper shunt between handles
• All clips supplied with copper cable lug, screw and nut

CAT NO. MATERIAL MAX. AMPS JAW OPENING mm


H811 2mm Copper Bronze 200 38
H812 2mm Steel Zinc plated 100 38

ALLIGATOR CLIPS
Utilux Battery Charging Clips have a high standard zinc chromate
finish suitable for constant potential or series charging
• All clips feature pan head screw to ensure perfect contact

CAT NO. DESCRIPTION


H141 Nickel Plated brass 5 amp clip
H2790 Nickel Plated brass 5 amp clip with barrel

TEST CLIPS
CAT NO. DESCRIPTION
H143 25 amp zinc plated steel test clip
H144 50 amp zinc plated steel test clip
H145 10 amp zinc plated steel test clip
H170 15 amp zinc plated steel test clip

ALLIGATOR AND TEST CLIP INSULATORS

INSULATOR PACKET OF PACKET OF 12 PACKET OF 12


FOR 6 RED & 6 BLACK RED BLACK
H170 H2082
H143 H2083RD H2083BK
H144 H2084 H2084RD H2084BK
H2790 H2796 H2796RD H2796BK

95
CABLE MANAGEMENT

STAINLESS STEEL BAND CLAMP & BUCKLES


• Versatile • Durable • Ease of handling • Low cost
BAND AND BUCKLES: • stainless steel minimising corrosion • width: 10, 12, 16, 19mm
• supplied in dispensers of 30m • available in matt finish

BAND CLAMP – MATT WIDTH


BUCKLES TOOLING
CAT. NO. mm
H3013M-30 9.5 H3001
H3016M-30 12 H3004
#46
H3019M-30 16 H3007
H3022M-30 19 H3010

SHEATHED BAND CLAMP


• 316 grade stainless steel band clamp
• Coated with halogen free, fire retardant, low smoke compound
• High strength corrosion resistant strapping
• Ideal for applications where safe evacuation, due to a fire
could become hazardous

WIDTH THICKNESS COATING


CAT. NO. BUCKLE TOOLING
mm mm mm
H82400-20 12.7 0.95 0.4 H82401 #115

#46 BAND CLAMP TOOL


• Manufactured from high tensile steel
• Machine threaded tension screw
• One tool for all band widths

96
CABLE MANAGEMENT

NYLON BAND CLAMP


• Flexible banding system for securing objects of any size
• Made from Nylon 6.6, impervious to atmospheric corrosion and resistant to most solvents and chemicals
• Cut to any length – reduces inventory and ensures you always have the correct size at hand
• Moulds to the contours of the product for secure grip • Temperature range of -400C to +1500C
• Available in customer specific colours (min quantity applies)
• Merchandise pack of band & buckles available for 4mm & 7mm
• Bulk packs of band & buckles available (min quantity applies)

TENSILE BAND RELEASABLE BUCKLES PERMANENT BUCKLES


SIZE
STRENGTH P/N PACK SIZE P/N PACK SIZE P/N PACK SIZE
4 250Nts NBC4 25m - - PB4 200
7 500Nts NBC7 20m RB7 50, 200 PB7 100
10 1750Nts NBC10 15m, 80m RB10 40, 200 - -

#117 NYLON BAND FITTING TOOL


• Single handed operation • Can be used whilst wearing gloves
• Designed for use at any angle • Designed for band teeth to strip if excessive pressure applies
LENGTH: 270mm • WEIGHT: 500gms

97
CABLE MANAGEMENT

UTI-TIES
• Durable • Available in natural finish or weather resistant black
• Smooth edges to avoid cuts • Tapered tip for ease of use
• Self locking system resists slippage

STANDARD NYLON TIES

NATURAL WEATHER RESISTANT LENGTH WIDTH MAX BUNDLE TENSILE PACK


DESCRIPT. CAT NO. DESCRIPT. CAT NO. (mm) (mm) DIA (mm) STRENGTH (KG) QTY
CT802 H31800 CT802W H31820 80 2.5 12 8 100/1000
CT1002 H31801 CT1002W H31821 102 2.5 16 8 100/1000
CT1503 H31802 CT1503W H31822 150 3.6 32 13 100/1000
CT2004 H31803 CT2004W H31823 200 4.8 44 22 100/1000
CT3004 H31804 CT3004W H31824 300 4.8 76 22 100/1000
CT3704 H31806 CT3704W H31826 370 4.8 102 22 100/1000

HEAVY DUTY NYLON TIES

NATURAL WEATHER RESISTANT LENGTH WIDTH MAX BUNDLE TENSILE PACK


DESCRIPT. DESCRIPT. (mm) (mm) DIA (mm) STRENGTH (KG) QTY
CT3807 CT3807W 380 7.6 102 54 100/1000
CT5507W 550 7.6 160 54 100/1000

EXTRA HEAVY DUTY NYLON TIES

LENGTH WIDTH MAX BUNDLE TENSILE PACK


DESCRIPT.
(mm) (mm) DIA (mm) STRENGTH (KG) QTY
CT55012W 550 12.7 160 110 100

STAINLESS STEEL CABLE TIES

LENGTH WIDTH MAX BUNDLE TENSILE PACK


DESCRIPT.
(mm) (mm) DIA (mm) STRENGTH (KG) QTY
CT2004SS 200 4.6 50 44 10/100
CT3604SS 360 4.6 100 44 10/100
CT5204SS 520 4.6 150 44 10/100
CT6804SS 680 4.6 200 44 10/100

STAINLESS STEEL CABLE TIES – HEAVY DUTY

LENGTH WIDTH MAX BUNDLE TENSILE PACK


DESCRIPT.
(mm) (mm) DIA (mm) STRENGTH (KG) QTY
CT2008SS 200 8 50 111 50
CT3608SS 360 8 100 111 50

CABLE TIE MOUNTS - 4 WAY

LENGTH WIDTH PACK


DESCRIPT. HEIGHT
(mm) (mm) QTY
TM19194 19 19 4 100
TM28284 28 28 4 100

98
CABLE MANAGEMENT

UTI-TIE INSTALLATION TOOL #101

DESCRIPTION

FEATURES ............................ Budget, Light weight


RANGE................................... Suitable for 2 to 5mm wide Uti-Ties
SIZE ........................................ 175mm
WEIGHT ................................. 60g

UTI-TIE INSTALLATION TOOL #TG9

DESCRIPTION

FEATURES ............................ Heavy duty steel, manual cut off


RANGE................................... Suitable for 2.5 to 10mm wide Uti Ties
SIZE ........................................ 190mm
WEIGHT ................................. 320g

UTI-TIE INSTALLATION TOOL #69

DESCRIPTION

FEATURES ............................ Robust, Tension adjusting dial, auto cut off


RANGE................................... Suitable for 2 to 4.8mm wide Uti-Ties
SIZE ........................................ 165mm
WEIGHT ................................. 210g

STAINLESS STEEL CABLE TIE TENSIONER #116


9
DESCRIPTION

FEATURES ............................ Manual cut off


RANGE................................... Suitable for all stainless steel ties
SIZE ........................................ 210mm
WEIGHT ................................. 570g

99
CABLE MANAGEMENT

NYLON HOSE CLIPS

DESCRIPTION

• World acclaimed hose fastening system


• One piece, durable Nylon 66 moulding
• High integrity clamping by double row of interlocking teeth
• Fast easy fitting and release
• High resistance to corrosion and solvent attack
• 200psi clamp force with only 3 teeth engaged

PART HOSE DIAMETER BAND REF


NO. MIN MAX OPTIMUM WIDTH NO.
HCN7 5.6 6.8 6.5 4.2 A
HCN8 6.5 8.1 7.9 4.5 AA
HCN9 7.9 9.6 9.2 4.4 B
HCN10 9.2 10.8 10.3 4.5 BB
HCN12 10.2 12.3 11.8 5.8 C
HCN13 11.1 13.4 12.9 6.1 CC
HCN14 12.0 14.5 13.8 6.1 D
HCN15 13.1 15.7 15.1 7.2 E
HCN17 15.0 17.8 17.1 7.1 F
HCN19 16.9 19.9 19.1 6.9 G
HCN21 18.1 21.4 20.6 7.1 H
HCN23 20.3 23.7 23.0 6.4 J
HCN25 22.2 25.8 24.9 7.0 K
HCN28 24.5 28.4 27.6 7.1 L
HCN30 26.5 30.4 29.5 7.4 M
HCN32 28.8 33.0 32.2 9.0 N
HCN35 32.0 35.6 34.8 9.1 P
HCN38 34.3 38.7 37.9 8.9 Q

Complete range of Clips to suit hose diameters from 5.6mm to 171mm. Refer to Tyco Sales Department for full listing.

ver you nee


e
d
t
wha

P
L

C
AN HE

100
CONTENTS

TECHNICAL DATA SECTION 10

SECTION 10 UTILUX EXPRESS REFERENCE


TABLES TOOL SELECTION CHARTS . . . . . . . . . . . . . . . . . . . . . . . . .101
UTILUX EXPRESS ORDER FORMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
CONVERSION TABLES FOR
NON-METRIC CABLE SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
USEFUL REFERENCE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
COMPRESSION TERMINATION THEORY . . . . . . . . . . . . . . . . . . . . . . . . . . .119
BASIC COMPRESSION TERMINATION PRACTICES . . . . . . . . . . . . . . . . . . .119
TERMINATION RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
FLEXIBLE CABLE CRIMPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
METRIC DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
ERGONOMIC DESIGN – . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123

CATALOGUE INDEX INDEX


SPECIAL PRODUCT ORDER
EXPRESS FAX (02) 4353 2470 EXPRESS FAX (02) 4353 2470 EXPRESS FAX (02) 4353 2470

1. Tick a box to identify the standard


blank which is closest to your
COPPER LUGS
required design.
2. Complete the Conductor Details
section inserting your requirements.
3. Enter your required dimensions
staying within the guidelines in the
standards table.
4. Complete customer contact and
authorisation details.
5. Fax to Utilux Express.

1. STANDARDS & GUIDELINES All dimensions in mm


Catalogue Conductor A B C D E F L M
No. Range mm 2 Min Max Ref Ref Max Max Max Max
❏ CGX25/1 25 8.0 54 16.7 1.9 70 40 115 M10
❏ CGX35/1 35 8.0 74 18.2 2.7 90 45 140 M12
❏ CGX50/1 50 11.0 78 20.6 2.8 100 50 159 M12
❏ CGX70/1 70 11.0 78 21.0 3.2 100 50 161 M12
❏ CGX 95/1 95 12.0 76 25.0 4.0 100 50 163 M12
❏ CGX120/1 120 15.0 70 30.0 4.8 100 50 165 M20
❏ CGX150/1 150 18.0 64 34.0 5.4 100 50 166 M20
❏ CGX185/1 185 18.0 64 37.0 5.2 100 55 173 M20
❏ CGX240/1 240 23.0 64 42.0 7.1 110 60 191 M20
❏ CGX300/1 300 23.0 64 46.0 7.9 110 60 192 M20
❏ CGX400/1 400 23.0 64 49.6 7.9 110 70 207 M20
❏ CGX500/1 500 23.0 64 54.8 8.2 110 70 213 M20
❏ CGX630/1 630 25.0 50 63.5 11.5 100 70 205 M20

2. CONDUCTOR DETAILS 3. REQUIRED SPECIFICATIONS


Dimensions: A: mm B: mm 2 E: mm

Stranding:
F: mm L: mm Stud M: mm

Area: mm 2

Qty:
Type: Flexible ❏ Comments
Solid ❏
Stranded ❏
Compacted ❏

4. CUSTOMER DETAILS
Company Order No. Date

Email Contact Date Required


Approved By
Telephone
Approval Signature
Facsimile

5. Print & Fax this to UTILUX EXPRESS - (02) 4353 2470 Print Order
Specially manufactured products cannot be returned for credit.
102
SPECIAL PRODUCT ORDER
EXPRESS FAX (02) 4353 2470 EXPRESS FAX (02) 4353 2470 EXPRESS FAX (02) 4353 2470

1. Tick a box to identify the standard


blank which is closest to your
COPPER LINKS
required design.
2. Complete the Conductor Details
section inserting your requirements.
3. Enter your required dimensions
staying within the guidelines in the
standards table.
4. Complete customer contact and
authorisation details.
5. Fax to Utilux Express.

1. STANDARDS & GUIDELINES All dimensions in mm


Catalogue No. Conductor F G
Range mm 2 Recommended Lengths

❏ CKX10-35/1 10-35 24 24

❏ CKX50-70/1 50-70 24 24

❏ CKX95-120/1 95-120 38 38

❏ CKX150-185/1 150-185 38 38

❏ CKX240-300/1 240-300 44 44

❏ CKX400-500/1 400-500 59 59

❏ CKX630/1 630 59 59

2. CONDUCTOR DETAILS 3. REQUIRED SPECIFICATIONS


LARGE END SMALL END Dimensions: F: mm G: mm

Stranding: Stranding:

Area : mm 2 Area: mm 2
Qty:

Type: Flexible ❏ Comments


Solid ❏
Stranded ❏
Compacted ❏

4. CUSTOMER DETAILS
Company Order No. Date

Email Contact Date Required 10


Approved By
Telephone
Approval Signature
Facsimile

5. Print & Fax this to UTILUX EXPRESS - (02) 4353 2470 Print Order
Specially manufactured products cannot be returned for credit.
103
SPECIAL PRODUCT ORDER
EXPRESS FAX (02) 4353 2470 EXPRESS FAX (02) 4353 2470 EXPRESS FAX (02) 4353 2470

1. Tick a box to identify the standard


blank which is closest to your
BI-METAL LINKS
required design.
2. Complete the Conductor Details Aluminium Copper
section inserting your requirements.
3. Enter your required dimensions
staying within the guidelines in the
standards table.
4. Complete customer contact and
authorisation details.
5. Fax to Utilux Express.

1. STANDARDS & GUIDELINES All dimensions in mm


Catalogue No. Conductor F G L
Range mm 2 Max Max Max

❏ BKX10-35/1 10-35 21.5 32 70

❏ BKX50-70/1 50-70 21.5 32 70

❏ BKX95-120/1 95-120 40 60 120

❏ BKX150-185/1 150-185 40 60 120

❏ BKX240-300/1 240-300 40 60 120

❏ BKX400-630/1 400-630 60 70 160

2. CONDUCTOR DETAILS 3. REQUIRED SPECIFICATIONS


LARGE END SMALL END Dimensions: F: mm G: mm
Material: Al Material: Cu
Stranding: Stranding:
Area : mm 2 Area: mm 2
Qty:

Comments
Type: Flexible ❏
Solid ❏
Stranded ❏
Compacted ❏

4. CUSTOMER DETAILS
Company Order No. Date

Email Contact Date Required


Approved By
Telephone
Approval Signature
Facsimile

5. Print & Fax this to UTILUX EXPRESS - (02) 4353 2470 Print Order
Specially manufactured products cannot be returned for credit.
104
SPECIAL PRODUCT ORDER
EXPRESS FAX (02) 4353 2470 EXPRESS FAX (02) 4353 2470 EXPRESS FAX (02) 4353 2470

1. Tick a box to identify the standard


blank which is closest to your
ALUMINIUM LINKS
required design.
2. Complete the Conductor Details
section inserting your requirements.
3. Enter your required dimensions
staying within the guidelines in the
standards table.
4. Complete customer contact and
authorisation details.
5. Fax to Utilux Express.

1. STANDARDS & GUIDELINES All dimensions in mm


Catalogue No. Conductor F G
Range mm 2 Recommended Lengths

❏ AKX10-35/1 10-35 32 32

❏ AKX50-70/1 50-70 32 32

❏ AKX95-120/1 95-120 60 60

❏ AKX150-185/1 150-185 60 60

❏ AKX240-300/1 260-300 60 60

❏ AKX400-630/1 400-630 70 70

2. CONDUCTOR DETAILS 3. REQUIRED SPECIFICATIONS


LARGE END SMALL END Dimensions: F: mm G: mm

Stranding: Stranding:
Qty:
Area: mm 2 Area: mm 2

Comments
Type: Flexible ❏
Solid ❏
Stranded ❏
Compacted ❏

4. CUSTOMER DETAILS
Company Order No. Date

Email Contact Date Required 10


Approved By
Telephone
Approval Signature
Facsimile

5. Print & Fax this to UTILUX EXPRESS - (02) 4353 2470 Print Order
Specially manufactured products cannot be returned for credit.
105
SPECIAL PRODUCT ORDER
EXPRESS FAX (02) 4353 2470 EXPRESS FAX (02) 4353 2470 EXPRESS FAX (02) 4353 2470

1. Tick a box to identify the standard


blank which is closest to your
BI-METAL
required design. STALK LUGS
2. Complete the Conductor Details
Aluminium Copper
section inserting your requirements.
3. Enter your required dimensions
staying within the guidelines in the
standards table.
4. Complete customer contact and
authorisation details.
5. Fax to Utilux Express.

1. STANDARDS & GUIDELINES All dimensions in mm


Catalogue No. Conductor D E F L
Range mm 2 Max Max Max Max
❏ BSX10-35/1 10-35 12 30 32 70

❏ BSX50-70/1 50-70 16 30 32 70

❏ BSX95-120/1 95-120 22 50 60 120

❏ BSX150-185/1 150-185 26 50 60 120

❏ BSX240-300/1 240-300 33 50 60 120

❏ BSX400-630/1 400-630 45 70 70 160

2. CONDUCTOR DETAILS 3. REQUIRED SPECIFICATIONS


LARGE END SMALL END Dimensions: D: mm E: mm F: mm
Material: Al Material: Cu
Stranding: Diameter : mm

Area : mm 2
Qty:

Comments
Type: Flexible ❏
Solid ❏
Stranded ❏
Compacted ❏

4. CUSTOMER DETAILS
Company Order No. Date

Email Contact Date Required


Approved By
Telephone
Approval Signature
Facsimile

5. Print & Fax this to UTILUX EXPRESS - (02) 4353 2470 Print Order
Specially manufactured products cannot be returned for credit.
106
SPECIAL PRODUCT ORDER
EXPRESS FAX (02) 4353 2470 EXPRESS FAX (02) 4353 2470 EXPRESS FAX (02) 4353 2470

1. Tick a box to identify the standard


blank which is closest to your
COPPER STALK LUGS
required design.
2. Complete the Conductor Details
section inserting your requirements.
3. Enter your required dimensions
staying within the guidelines in the
standards table.
4. Complete customer contact and
authorisation details.
5. Fax to Utilux Express.

1. STANDARDS & GUIDELINES All dimensions in mm


Catalogue No. Conductor D E F
Range mm 2 Max Max Recommended
❏ CSX10-35/1 10-35 12 50 21.5

❏ CSX50-70/1 50-70 16 50 21.5

❏ CSX95-120/1 95-120 22 50 35

❏ CSX150-185/1 150-185 26 70 35

❏ CSX240-300/1 240-300 33 90 50

❏ CSX400-500/1 400-500 39 100 60

2. CONDUCTOR DETAILS 3. REQUIRED SPECIFICATIONS


LARGE END SMALL END Dimensions: D: mm E: mm F: mm
Material: Cu Material: Cu
Stranding: Diameter: mm

Area : mm 2
Qty:

Comments
Type: Flexible ❏
Solid ❏
Stranded ❏
Compacted ❏

4. CUSTOMER DETAILS
Company Order No. Date

Email Contact Date Required 10


Approved By
Telephone
Approval Signature
Facsimile

5. Print & Fax this to UTILUX EXPRESS - (02) 4353 2470 Print Order

Specially manufactured products cannot be returned for credit.


107
TECHNICAL DATA

CONVERSION TABLES FOR NON-METRIC CABLE SIZES

BRITISH METRIC AMERICAN METRIC AMERICAN METRIC


STANDARD EQUIVALENT WIRE GUAGE EQUIVALENT WIRE GUAGE EQUIVALENT
WIRE GUAGE SWG (sqmm) AWG (sqmm) AWG (sqmm)
33 0.0507 30 0.0507 250 MCM 127
32 0.0591 29 0.0645 300 MCM 152
31 0.0682 28 0.0806 350 MCM 177
30 0.0779 27 0.102 400 MCM 203
29 0.0937 26 0.128 450 MCM 228
28 0.0111 25 0.163 500 MCM 253
27 0.0136 24 0.205 550 MCM 279
26 0.0164 23 0.259 600 MCM 304
25 0.0203 22 0.324 650 MCM 329
24 0.0245 21 0.412 700 MCM 355
23 0.0292 20 0.519 750 MCM 380
22 0.0397 19 0.652 800 MCM 405
21 0.0519 18 0.826 850 MCM 431
20 0.0657 17 1.04 900 MCM 456
19 0.81 16 1.31 950 MCM 481
18 1.17 15 1.65 1000 MCM 507
17 1.59 14 2.08 1100 MCM 557
16 2.08 13 2.63 1200 MCM 608
15 2.63 12 3.31 1300 MCM 659
14 3.24 11 4.17 1400 MCM 709
13 4.29 10 5.26 1500 MCM 760
12 5.48 9 6.63 1600 MCM 811
10 8.30 8 8.37 1700 MCM 861
7 10.6 1800 MCM 912
6 13.3 1900 MCM 963
IMPERIAL METRIC 5 16.8 2000 MCM 1010
(sqIN) EQUIVALENT 4 21.2
(sqmm) 3 26.7
0.001 0.657 2 33.6
0.0015 0.981 1 42.4
0.002 1.28 0 53.5
0.003 1.97 2/0 67
0.0032 2.08 3/0 85
0.0045 2.98 4/0 107
0.007 4.60
0.01 6.81
0.0145 9.59
0.0225 14.5
0.03 18.6
0.04 26.0
0.06 39.4
0.075 49.9
0.1 66.3
0.12 76.8
0.15 97.2
0.2 129
0.25 162
0.3 199
0.4 267
0.5 328
0.6 399
0.75 489
0.85 557
1.0 683
1.25 807
1.5 1050

108
TECHNICAL DATA

USEFUL REFERENCE TABLES


APPENDIX A
FITTINGS FOR BARE OVERHEAD ALL ALUMINIUM CONDUCTORS (AAC)

CODE NON TENSION FULL TENSION JUMPER ALUMINIUM LUG ALUMINIUM LUG TERM. ADAPTOR BI-METAL LUG
STRAND
NAME SLEEVE DIE SLEEVE DIE SLEEVE DIE 1 HOLE DIE 2 HOLE DIE TYPE DIE DIE
Gemini 7/1.75 NT36 38-132AL FT36A 38-132AL JS36R 38-132AL SL36 38-132AL AL36 38-132AL BA36 38-132AL H15304 38-90AL
Jupitor 7/2.25 NT36 38-140AL FT36A 38-140AL JS36R 38-140AL SL36 38-140AL AL36 38-140AL BA36 38-140AL H15306 38-90AL
Leo 7/2.50 NT36 38-140AL FT36A 38-140AL JS36R 38-140AL SL36 38-140AL AL36 38-140AL BA36 38-140AL H15308 38-90AL
Leondis 7/2.75 NT44 38-173AL FT44A 38-173AL JS44R 38-173AL SL44 38-173AL AL44 38-173AL H15308 38-90AL
Libra 7/3.00 NT44 38-180AL FT44A 38-180AL JS44R 38-180AL SL44 38-180AL AL44 38-180AL H15311 38-132AL
Mars 7/3.75 NT50 38-180AL FT50A 38-180AL JS50R 38-180AL SL50 38-180AL AL50 38-180AL BA50 38-180AL H15317 38-173AL
Mercury 7/4.50 NT58 38-190AL FT58A 38-190AL JS58R 38-190AL SL58 38-190AL AL58 38-190AL BA58 38-190AL H15320 38-173AL
Mercury 7/4.50 NT61 38-220AL FT61A 38-220AL JS61R 38-220AL SL61 38-220AL AL61 38-220AL BA61 38-220AL H15320 38-173AL
Moon 7/4.75 NT61 38-220AL FT61A 38-220AL JS61R 38-220AL SL61 38-220AL AL61 38-220AL BA61 38-220AL H15320 38-173AL
Neptune 19/3.25 NT68 38-220AL FT68A 38-220AL JS68R 38-220AL SL68 38-220AL AL68 38-220AL BA68 38-220AL H15323 38-220AL
Orion 19/3.50 NT80 38-250AL FT80A 38-250AL JS80R 38-250AL SL80 38-250AL AL80 38-250AL BA80 38-250AL H15326 38-220AL
Pluto 19/3.75 NT80 38-262AL FT80A 38-262AL JS80R 38-262AL SL80 38-262AL AL80 38-262AL BA80 38-262AL H15329 38-284AL
Saturn 37/3.00 NT94 38-284AL FT94A 38-284AL JS94R 38-284AL SL94 38-284AL AL94 38-284AL H15332 38-284AL
Sirius 37/3.25 NT94 38-284AL FT94A 38-284AL JS94R 38-284AL SL94 38-284AL AL94 38-284AL H15332 38-284AL
Taurus 19/4.75 NT94 38-303AL FT94A 38-303AL JS94R 38-303AL SL94 38-303AL AL94 38-303AL H15334 38-390AL
Triton 37/3.75 NT114 40-432AL FT114A 40-432AL

FITTINGS FOR BARE OVERHEAD ALUMINIUM CONDUCTORS STEEL REINFORCED (ACSR)

CODE NON TENSION FULL TENSION JUMPER ALUMINIUM LUG ALUMINIUM LUG TERM. ADAPTOR BI-METAL LUG
STRAND
NAME SLEEVE DIE SLEEVE DIE SLEEVE DIE 1 HOLE DIE 2 HOLE DIE TYPE DIE DIE
Quince 3/4/1.75 NT36 38-132AL JS36R 38-132AL SL36 38-132AL AL36 38-132AL BA36 38-132AL H15304 38-90AL
Almond 6/1/2.50 NT36 38-140AL JS36R 38-140AL SL36 38-140AL AL36 38-140AL BA36 38-140AL H15308 38-90AL
Raisin 3/4/2.50 NT36 38-140AL JS36R 38-140AL SL36 38-140AL AL36 38-140AL BA36 38-140AL H15308 38-90AL
Apricot 6/1/2.75 NT44 38-173AL FT44R 38-173AL JS44R 38-173AL SL44 38-173AL AL44 38-173AL BA44 38-173AL H15308 38-90AL
Apple 6/1/3.00 NT44 38-173AL FT44R 38-173AL JS44R 38-173AL SL44 38-173AL AL44 38-173AL BA44 38-173AL H15311 38-132AL
Sultana 4/3/3.00 NT44 38-180AL JS44R 38-180AL SL44 38-180AL AL44 38-180AL BA44 38-180AL H15311 38-132AL
Banana 6/1/3.75 NT50 38-180AL FT50R 38-180AL JS50R 38-180AL SL50 38-180AL AL50 38-180AL BA50 38-180AL H15317 38-173AL
Walnut 4/3/3.75 NT50 38-180AL JS50R 38-180AL SL50 38-180AL AL50 38-180AL BA50 38-180AL H15317 38-173AL
6/4.75
Cherry NT61 38-220AL FT61R 38-220AL JS61R 38-220AL SL61 38-220AL AL61 38-220AL BA61 38-220AL H15320 38-173AL
7/1.60
Grape 30/7/2.50 NT80 38-250AL JS80R 38-250AL SL80 38-250AL AL80 38-250AL H15326 38-220AL
Fig 18/1/3.50 NT80 38-250AL JS80R 38-250AL SL80 38-250AL AL80 38-250AL H15326 38-220AL
Lemon 30/7/3.00 NT94 38-284AL

10

109
TECHNICAL DATA

USEFUL REFERENCE TABLES


AUSTRALIAN STANDARD METRIC CONDUCTORS
ACSR/AC – ALUMINIUM CONDUCTOR (ALUMINIUM CLAD) STEEL REINFORCED. Aust. Standard – AS1220 PART 3

STRANDS/ OVERALL CALCULATED CALCULATED APPROXIMATE


CODE WIRE DIAMETER EQUIVALENT SECTIONAL MINIMUM MASS
NAME DIAMETER (APPROX) ALUMINIUM AREA BREAKING PER KM
mm mm AREA mm2 mm2 LOAD kN kg
Angling 6/1/2.50 7.50 30.7 34.36 10.7 113
Archery 6/1/3.00 9.00 44.1 49.48 15.0 163
Baseball 6/1/3.75 11.3 68.9 77.31 22.4 255
Bowls 6/4.75+7/1.60 14.3 109 120.4 32.6 385
Cricket 30/7/2.50 17.5 155 181.6 64.6 635
Darts 30/7/3.00 21.0 224 261.5 91.3 913
Diving 30/7/3.50 24.5 305 356.0 121 1240
Golf 54/7/3.00 27.0 390 431.2 119 1380
Gymnastics 54/7/3.25 29.3 457 506.0 138 1620
Hurdles 54/7/3.50 31.5 530 586.9 159 1880
Lacrosse 54/3.75+19/2.25 33.8 608 671.7 181 2150
Rugby 54/4.75+19/2.85 42.8 976 1078 287 3450
EXTRA HIGH STRENGTH
Skating 3/4/1.75 5.25 10.4 16.84 12.3 83.5
Soccer 3/4/2.50 7.50 21.2 34.36 24.9 170
Swimming 4/3/3.00 9.00 35.2 49.48 28.8 217
Tennis 4/3/3.75 11.3 54.9 77.31 42.8 339

ver you nee


e
d
t
wha

P
L

C
AN HE

110
TECHNICAL DATA

USEFUL REFERENCE TABLES


AUSTRALIAN STANDARD METRIC CONDUCTORS
AAC – ALL ALUMINIUM CONDUCTOR Aust. Standard – AS1531 PART 1

STRANDS/ OVERALL CALCULATED CALCULATED APPROXIMATE


CODE WIRE DIAMETER EQUIVALENT SECTIONAL MINIMUM MASS
NAME DIAMETER (APPROX) ALUMINIUM AREA BREAKING PER KM
mm mm AREA mm2 mm2 LOAD kN kg
Gemini 7/1.75 5.25 16.6 16.84 3.01 46.1
Jupiter 7/2.25 6.75 27.5 27.83 4.76 75.9
Leo 7/2.50 7.50 33.9 34.36 5.75 94.3
Libra 7/3.00 9.00 48.8 49.48 7.91 135
Mars 7/3.75 11.3 76.3 77.31 11.9 212
Mercury 7/4.50 13.5 110 111.3 16.8 305
Moon 7/4.75 14.3 122 124.0 18.8 340
Neptune 19/3.25 16.3 155 157.6 24.7 433
Pluto 19/3.75 18.8 206 209.8 32.3 578
Saturn 37/3.00 21.0 256 261.5 41.8 721
Taurus 19/4.75 23.8 331 336.7 50.9 926
Triton 37/3.75 26.3 400 408.7 62.9 1130
Uranus 61/3.25 29.3 493 506.0 75.2 1400
Venus 61/3.75 33.8 659 673.7 98.3 1860
Virgo 91/4.50 49.5 1410 1447 207 4010

AAAC – ALL ALUMINIUM ALLOY CONDUCTOR Aust. Standard – AS1531 PART 2

STRANDS/ OVERALL CALCULATED CALCULATED APPROXIMATE


CODE WIRE DIAMETER EQUIVALENT SECTIONAL MINIMUM MASS
NAME DIAMETER (APPROX) ALUMINIUM AREA BREAKING PER KM
mm mm AREA mm2 mm2 LOAD kN kg
Agate 7/1.75 5.25 14.3 16.84 4.71 46.1
Amethyst 7/2.25 6.75 23.7 27.83 7.78 75.9
Diamond 7/2.50 7.50 29.3 34.36 9.64 94.3
Emerald 7/3.00 9.00 42.1 49.48 13.9 135
Garnet 7/3.75 11.3 65.8 77.31 21.7 211
Jade 7/4.50 13.5 94.8 111.3 31.2 304
Jasper 7/4.75 14.3 106 124.0 34.8 339
Opal 19/3.25 16.3 134 157.6 44.2 433
Pearl 19/3.75 18.8 178 209.8 58.8 576
Ruby 37/3.00 21.0 221 261.5 73.5 721
Rutile 19/4.75 23.8 285 336.7 94.4 924
Sapphire 37/3.75 26.3 345 408.7 115 1120
Spinel 61/3.25 29.3 426 506.0 135 1400
Topaz 61/3.75 33.8 568 673.7 179 1860
Zircon 91/4.50 49.5 1220 1447 384 4000 10

111
TECHNICAL DATA

USEFUL REFERENCE TABLES


AUSTRALIAN STANDARD METRIC CONDUCTORS
SC/GZ – STEEL CONDUCTOR/GALVANISED Aust. Standard – AS1222 PART 1

STRANDS/WIRE OVERALL DIAMETER CALCULATED EQUIV. SECTIONAL CALCULATED MIN. APPROXIMATE


DIAMETER /mm (APPROX) mm ALUMINIUM AREA mm2 AREA mm2 BREAKING LOAD kN MASS PER Km kg
3/2.00 4.31 1.56 9.425 11.7 75.5
3/2.75 5.93 2.95 17.82 22.2 139
7/2.00 6.00 3.62 21.99 27.4 177
7/2.75 8.25 6.85 41.58 51.8 326
7/3.25 9.75 9.56 58.07 72.3 460
7/3.75 11.3 12.7 77.31 96.2 609
19/2.00 10.0 9.79 59.69 74.4 483
19/2.75 13.8 18.5 112.9 141.0 888
19/3.25 16.3 25.8 157.6 196.0 1250

SC/AC – STEEL CONDUCTOR/ALUMINIUM CLAD Aust. Standard – AS1222 PART 2

STRANDS/WIRE OVERALL DIAMETER CALCULATED EQUIV. SECTIONAL CALCULATED MIN. APPROXIMATE


DIAMETER /mm (APPROX) mm ALUMINIUM AREA mm2 AREA mm2 BREAKING LOAD kN MASS PER Km kg
3/2.75 5.93 5.91 17.82 22.7 118
3/3.00 6.47 7.03 21.21 27.0 141
3/3.25 7.00 8.26 24.89 31.6 165
3/3.75 8.08 11.0 33.13 40.0 220
7/2.75 8.25 13.7 41.58 50.1 277
7/3.00 9.00 16.3 49.48 59.7 330
7/3.25 9.75 19.2 58.07 69.8 387
7/3.75 11.3 25.5 77.31 88.3 515
7/4.25 12.8 32.8 99.3 106 662
19/2.75 13.8 37.1 112.9 136 755
19/3.00 15.0 44.1 134.3 162 899
19/3.25 16.3 51.8 157.6 189 1060
19/3.75 18.8 68.9 209.8 240 1410
19/4.25 21.3 88.6 269.5 289 1800

HDC – HARD DRAWN COPPER CONDUCTOR Aust. Standard – AS1746 1975

STRANDS/WIRE OVERALL DIAMETER CALCULATED EQUIV. SECTIONAL CALCULATED MIN. APPROXIMATE


DIAMETER /mm (APPROX) mm ALUMINIUM AREA mm2 AREA mm2 BREAKING LOAD kN MASS PER Km kg
7/1.00 3.00 8.68 5.498 2.31 49.3
7/1.25 3.75 13.6 8.589 3.61 76.9
7/1.75 5.25 26.6 16.84 6.89 151
7/2.00 6.00 34.7 21.99 9.02 197
7/2.75 8.25 65.3 41.58 16.7 375
7/3.50 10.5 106 67.35 26.6 607
19/1.75 8.75 71.7 45.70 18.3 413
19/2.00 10.0 93.7 59.69 23.9 538
19/2.75 13.8 177 112.9 44.5 1020
19/3.00 15.0 211 134.3 52.8 1210
37/1.75 12.3 139 89.0 35.6 806
37/2.50 17.5 284 181.6 72.9 1640
37/2.75 19.3 344 219.8 86.6 1990
37.3.00 21.0 409 261.5 103 2370
61/2.75 24.8 566 362.3 143 3280

112
TECHNICAL DATA

USEFUL REFERENCE TABLES


AUSTRALIAN STANDARD METRIC CONDUCTORS
ACSR/GZ – ALUMINIUM CONDUCTOR (GALVANISED) STEEL REINFORCED. Aust. Standard – AS1220 PART 1

STRANDS/ OVERALL CALCULATED CALCULATED APPROXIMATE


CODE WIRE DIAMETER EQUIVALENT SECTIONAL MINIMUM MASS
NAME DIAMETER (APPROX) ALUMINIUM AREA mm2 BREAKING PER KM
mm mm AREA mm2 LOAD kN kg
Almond 6/1/2.50 7.50 29.0 34.36 10.5 119
Apple 6/1/3.00 9.00 41.8 49.48 14.9 171
Banana 6/1/3.75 11.3 65.2 77.31 22.8 268
Cherry 6/4.75 + 7/1.60 14.3 105 120.4 33.2 404
Grape 30/7/2.50 17.5 144 181.6 63.7 675
Lemon 30/7/3.00 21.0 207 261.5 90.1 973
Lime 30/7/3.50 24.5 282 356.0 121 1320
Mango 54/7/3.00 27.0 373 431.2 118 1440
Orange 54/7/3.25 29.3 438 506.0 137 1690
Olive 54/7/3.50 31.5 508 586.9 159 1960
Paw Paw 54/3.75 + 19/2.25 33.8 583 671.7 179 2250
Peach 54/4.75 + 19/2.85 42.8 936 1078 284 3600
EXTRA HIGH STRENGTH
Quince 3/4/1.75 5.25 8.77 16.84 12.7 95.9
Raisin 3/4/2.50 7.50 17.9 34.36 24.4 193
Sultana 4/3/3.00 9.00 31.6 49.48 28.3 242
Walnut 4/3/3.75 11.3 49.4 77.31 43.9 379

ACSR/AZ – ALUMINIUM CONDUCTOR (ALUMINISED) STEEL REINFORCED. Aust. Standard – AS1220 PART 2

STRANDS/ OVERALL CALCULATED CALCULATED APPROXIMATE


CODE WIRE DIAMETER EQUIVALENT SECTIONAL MINIMUM MASS
NAME DIAMETER (APPROX) ALUMINIUM AREA mm2 BREAKING PER KM
mm mm AREA mm2 LOAD kN kg
Barley 6/1/2.50 7.50 29.0 34.36 10.3 119
Bean 6/1/3.00 9.00 41.8 49.48 14.5 171
Cabbage 6/1/3/75 11.3 65.2 77.31 21.5 268
Carrot 6/4.75 + 7/1.60 14.3 105 120.4 31.9 404
Corn 30/7/2.50 17.5 144 181.6 61.6 675
Garlic 30/7/3.00 21.0 207 261.5 87.2 973
Millet 30/7/3.50 24.5 282 356.0 116 1320
Oats 54/7/3.00 27.0 373 431.2 115 1140
Onion 54/7/3.25 29.3 438 506.0 132 1690
Parsnip 54/7/3.50 31.5 508 586.9 153 1960
Potato 54/3.75 + 19/2.25 33.8 583 671.7 177 2250
Rice 54/4.75 + 19/2.85 42.8 936 1078 277 3600

10

113
TECHNICAL DATA

USEFUL REFERENCE TABLES


A.C.S.R. CONDUCTOR SIZES

METRIC IMPERIAL
CONDUCTOR O.D. O.D.
CODE NAME STRANDING CODE NAME STRANDING
mm inches inches
Almond 6/2.50 + 1/2.50 7.50 .295 Gopher 6/1/093 .279
Apple 6/3.00 + 1/3.00 9.00 .354 Ferret 6/1/118 .354
Banana 6/3.75 + 1/3.75 11.3 .445 Mink 6/1/144 .432
Cherry 6/4.75 + 7/1.60 14.3 .563 Dog 6/186 + 7/062 .558
Grape 30/2.50 + 7/2.50 17.5 .689 Wolf 30/7/102 .714
Lemon 30/3.00 + 7/3.00 21.0 .827 Panther 30/7/118 .826
Lime 30/3.50 + 7/3.50 24.5 .965 Bear 30/7/132 .924
Mango 54/3.00 + 7/3.00 27.0 1.063 Bison 54/7/118 1.062
Orange 54/3.25 + 7/3.25 29.3 1.154 Brolga 54/7/129 1.162
Olive 54/3.50 + 7/3.50 31.5 1.240 Moose 54/7/139 1.251
Paw Paw 54/3.75 + 19/2.25 33.8 1.331 Finch 54/143 + 19/086 1.293

STRANDED HARD DRAWN COPPER CONDUCTOR SIZES

METRIC IMPERIAL
CONDUCTOR O.D. CONDUCTOR O.D.
CODE NAME CODE NAME
mm inches mm inches
7/1.00 3.00 .118 7/036 2.7 .108
7/1.25 3.75 .148 7/048 3.7 .144
7/1.75 5.25 .207 7/064 4.9 .192
7/2.0 6.00 .236 7/080 6.1 .240
7/2.75 8.25 .325 19/064 8.1 .320
19/1.75 8.75 .345 7/118 9.0 .354
19/2.0 10.0 .394 7/136 10.3 .408
7/3.50 10.5 .413 19/083 10.5 .415
37/1.75 12.25 .484 37/072 12.8 .504
19/2.75 13.75 .541 – – –
19/3.00 15.0 .591 19/116 14.7 .580
37/2.50 17.5 .689 37/093 16.5 .651
37/2.75 19.25 .758 37/103 18.3 .721
37/3.00 21.0 .827 37/118 21.0 .826
61/2.75 24.75 .974 91/093 26.0 1.023

114
TECHNICAL DATA

USEFUL REFERENCE TABLES


CABLE CROSS SECTIONS
ANNEALED ALUMINIUM AND COPPER STRANDED CONDUCTORS

METRIC IMPERIAL
NOMINAL NUMBER AND NOMINAL NOMINAL NOMINAL
NOMINAL NUMBER AND
CROSS NOMINAL CROSS CROSS DIA. OF
DIA. OF NOMINAL DIA.
SECTIONAL DIA. OF SECTIONAL SECTIONAL CONDUCTOR
CONDUCTOR DIA. OF WIRES
AREA WIRES AREA AREA
mm2 mm mm mm2 inches mm inches2 mm
1 1/1.13 1.13 .97 1/.044 1/1.12 .0015 1.12
– – – 1.25 3/.029 3/.737 .0019 1.59
1.5 1/1.38 1.38 – – – – –
– – – 1.93 3/.036 3/.914 .003 1.97
2.5 7/0.67 2.01 – – – – –
– – – 2.93 7/.029 7/.737 .0045 2.21
4 7/0.85 2.55 – – – – –
– – – 4.52 7/.036 7/.914 .007 2.74
6 7/1.04 3.12 – – – – –
– – – 6.75 7/.044 7/1.12 .010 3.35
– – – 9.43 7/.052 7/1.32 .0146 3.96
10 7/1.35 4.05 – – – – –
– – – 14.28 7/.064 7/1.63 .0025 4.88
16 7/1.70 5.10 – – – – –
– – – 18.29 19/.044 19/1.12 .03 5.59
25 7/2.14 6.75 25.5 19/.052 19/1.32 .04 6.60
35 19/1.53 7.65 – – – – –
– – – 38.7 19/.064 19/1.63 .06 8.13
50 19/1.78 8.90 – – – – –
– – – 65.1 19/.083 19/2.11 .10 10.5
70 19/2.14 10.70 – – – – –
– – – 75.3 37/.064 37/1.63 .12 11.4
95 19/2.52 12.60 95.3 37/.072 37/1.83 .15 12.8
120 37/2.03 14.21 126.7 37/.083 37/2.11 .20 14.8
150 37/2.25 15.75 – – – – –
– – – 159.1 37/.093 37/2.36 .25 16.5
185 37/2.52 17.64 – – – – –
– – – 195.1 37/.103 37/2.62 .30 18.3
240 61/2.25 20.25 – – – – –
– – – 262.2 61/.093 61/2.36 .40 21.3
300 61/2.52 22.68 – – – – –
– – – 321.6 61/.103 61/2.62 .50 23.5
– – – 391.1 91/.093 91/2.36 .60 26.0
400 61/2.85 25.65 – – – – –
10
– – – 479.7 91/.103 91/2.62 .75 28.8
500 61/3.20 28.80 – – – – –
630 127/2.52 32.76 – – – – –
– – – 669.4 127/.103 127/2.62 1.00 34.0
800 127/2.85 37.05 800.00 127/.112 127/2.84 1.24 36.92
1000 127/3.20 41.60 1000.0 127/.125 127/3.18 1.50 41.34

115
TECHNICAL DATA

USEFUL REFERENCE TABLES


OVERHEAD CONDUCTORS

AAC AAAC (1120) AAAC (6201A) ACSR


STRAND O.D. AREA STRAND O.D. AREA STRAND O.D. AREA STRAND O.D. AREA
CODE AL mm mm2 CODE AL mm mm2 CODE AL mm mm2 CODE AL mm mm2
Gemini 7/1.75 5.25 16.8 Argon 7/1.75 5.25 16.8 Agate 7/1.75 5.25 16.8 Quince* 3/4/1.75 5.25 16.8
Jupiter 7/2.25 6.75 27.8 Boron 7/2.25 6.75 27.8 Amethyst 7/2.25 6.75 27.8
Leo 7/2.50 7.50 34.4 Chlorine 7/2.50 7.50 34.4 Diamond 7/2.50 7.50 34.4 Almond 6/1/2.50 7.50 34.4
Raisin* 3/4/2.50 7.50 34.4
Leonids 7/2.75 8.25 41.6 Chronium 7/2.75 8.25 41.6 Dolomite 7/2.75 8.25 41.6
Libra 7/3.00 9.00 49.5 Fluorine 7/3.00 9.00 49.5 Emerald 7/3.00 9.00 49.5 Apple 6/1/3.00 9.00 49.5
Sultana* 4/3/3.00 9.00 49.5
Mars 7/3.75 11.25 77.3 Helium 7/3.75 11.25 77.3 Garnet 7/3.75 11.25 77.3 Banana 6/1/3.75 11.25 77.3
Walnut* 4/3/3.75 11.25 77.3
Mercury 7/4.50 13.50 111.3 Hydrogen 7/4.50 13.50 111.3 Jade 7/4.50 13.50 111.3
Moon 7/4.75 14.25 124.0 Iodine 7/4.75 14.25 124.0 Jasper 7/4.75 14.25 124.0
Cherry 6/4.75 14.30 120.4
7/1.60
Neptune 19/3.25 16.25 157.6 Krypton 19/3.25 16.25 157.6 Opal 19/3.25 16.25 157.6
Orion 19/3.50 17.50 182.8 Lutetium 19/3.50 17.50 182.50 Patronite 19/3.50 17.50 182.50 Grape 30/7/2.50 17.50 181.6
Pluto 19/3.75 18.75 209.8 Neon 19/3.75 18.75 209.8 Pearl 19/3.75 18.75 209.8
Saturn 37/3.00 21.00 261.5 Nitrogen 37/3.00 21.00 261.5 Ruby 37/3.00 21.00 261.5 Lemon 30/7/3.00 21.00 261.5
Sirius 37/3.25 22.75 306.9 Nobelium 37/3.25 22.75 306.9 Ruthenium 37/3.25 22.75 306.9
Taurus 19/4.75 23.75 336.7 Oxygen 19/4.75 23.75 336.7 Rutile 19/4.75 23.75 336.7
Lime 30/7/3.50 24.50 356.0
Triton 37/3.75 26.25 408.6 Phosphorus 37/3.75 26.25 408.6 Sapphire 37/3.75 26.25 408.6
Mango 54/7/3.00 27.00 431.2
Uranus 61/3.25 29.25 506.4 Selenium 61/3.25 29.25 506.4 Spinel 61/3.25 29.5 506.4 Orange 54/7/3.25 29.25 506.4
Ursula 61/3.50 31.50 586.9 Silicon 61/3.50 31.50 586.9 Tantalum 61/3.50 31.50 586.9 Olive 54/7/3.50 31.50 586.9
Venus 61/3.75 33.75 673.7 Sulphur 61/3.75 33.75 673.7 Topaz 61/3.75 33.75 673.7 Paw Paw 54/3.75 33.75 672.0
19/2.25
Peach 54/4.75 42.75 1078.0
19/2.85
Virgo 91/4.50 49.50 1447.0 Xenon 91/4.50 49.50 1447.0 Zircon 91/4.50 49.50 1447.0

116
TECHNICAL DATA

USEFUL REFERENCE TABLES


TOOL AND DIE SELECTION
STANDARD COPPER LUGS, LINKS, STALKS ETC.
HYDRAULIC TOOLS – HEXAGONAL DIES
CONDUCTOR DIE 12 TONNE
HAND 5 TONNE 22 TONNE 60 TONNE
SIZE A/F #38A #98
CRIMPERS #111 #66H #40B
mm2 mm #41AH #98H
1.5 –
#00 #102U

2.5 –
#16/1
4 –
6 4.4 38-44CU
#18/1

10 5.7 111-5763CU 38-57CU


16 6.3 111-5763CU 38-63CU
#21/1

25 7.7 111-7792CU 38-77CU USE


USE ADAPTOR
#22/1

35 9.2 111-7792CU 38-92CU


#20/1

STANDARD 40-DH AND


50 10.4 111-104115CU 38-104CU COPPER STANDARD
DIES 12 TONNE
70 11.5 111-104115CU 38-115CU DIES
95 14.2 111-142165CU 38-142CU
120 16.5 111-142165CU 38-160CU
150 18.3 38-183CU
185 20.0 38-200CU
240 23.1 38-231CU
300 26.0 38-260CU
400 28.1 66-281CU 40-281CU
500 31.0 66-310CU 40-310CU
630 37.0 40-370CU
800 43.2 40-432CU
100 48.0 40-489CU

STANDARD ALUMINIUM AND BI-METAL


HYDRAULIC TOOLS – HEXAGONAL DIES
CONDUCTOR DIE 12 TONNE
60 TONNE
SIZE A/F #38A #98A
#40B
mm2 mm #41AH #98H
1.5 –
2.5 –
4 –
6 9.0 38-90AL
10 9.0 38-90AL
16 9.0 38-90AL
25 9.0 38-90AL
35 9.0 38-90AL USE ADAPTOR 40DH
50 13.2 38-132AL AND STANDARD
12 TONNE DIES
70 13.2 38-132AL
95 17.3 38-173AL 10
120 17.3 38-173AL
150 22.0 38-220AL
185 22.0 38-220AL
240 28.4 38-284AL
300 28.4 38-284AL
400 39.0 40-390AL
500 39.0 40-390AL
630 43.2 40-432AL
800 43.2 40-525AL

117
TECHNICAL DATA

USEFUL REFERENCE TABLES


NOMINAL CABLE DIMENSIONS

O.D. OF O.D. OF
CROSS STRAND O.D. P.V.C. P.V.C. INS. O.D. OF TWO THREE FOUR
SECTION NO./WIRE OF SINGLE SINGLE SINGLE TWO CORE + CORE + CORE +
AREA DIA. CONDUCT CORE CORE CORE CORE EARTH EARTH EARTH
mm2 XLPE/PVC
CABLE SHEATHED
1/1.13 1.13
1 7/0.40 1.20 2.8 4.1

1/1.38 1.38
1.5 3.2 4.4 9.4
7/0.50 1.5
2.5 7/0.67 2.01 3.7 5.1 10.8
4 7/0.85 2.55 4.6 6.0 12.2
6 7/1.04 3.12 5.2 6.6 13.4
10 7/1.35 4.05 6.1 8.1 16.6 18.1 20.0
16 7/1.70 5.10 7.2 9.3 18.6 20.4 22.6
25 19/1.35 6.75 8.9 11.4 22.1 23.8 26.5
35 19/1.53 7.65 10.1 12.6 24.4 26.5 29.5
50 19/1.78 8.9 11.9 14.1 28.0 30.6 34.3
70 19/2.14 10.70 13.5 16.0 31.5 34.8 39.0
95 37/1.78 12.46 15.9 18.2 39.6 44.6
120 37/2.03 14.21 17.4 20.0 43.3 48.8
150 37/2.25 15.75 19.5 22.2 48.4 54.6
185 37/2.52 17.64 24.4 53.7 60.7
240 61/2.25 20.25 27.4 61.0 69.1
300 61/2.52 22.68 30.3 67.6 76.6
400 61/2.85 25.65 33.8
500 61/3.20 28.80 35.7
630 127/2.52 32.76 40.2

NOMINAL DATA AS SPECIFIED IN AS/NZS 5000 -1 & 2

ver you nee


e
d
t
wha

P
L

C
AN HE

118
TECHNICAL DATA

COMPRESSION TERMINATION THEORY


Utilux crimp lugs, links and stalk lugs are designed to be compatible with Utilux indent tools and hydraulic tools with
hexagonal or indent dies. Through this exact matching the resultant terminations achieve a consistently precise
compression – neither over stressed nor understressed – to produce the correct indent or hexagonal force.
The crimp is designed to bring all conductors and the connector itself into intimate contact. At the same time, the
crimp is designed to avoid any reduction in the cross sectional area of the conductor, with an increased contact area.

BASIC COMPRESSION TERMINATION PRACTICES


1. Strip the cable insulation to the recommended length. Recommended stripping lengths of conductors should
correspond to the barrel lengths shown in this catalogue.

2. With non plated copper conductors, scratch brushing may be carried out on the bare copper conductor.
On aluminium conductors however, scratch brushing must be carried out. Terminating should be
completed as soon as possible after stripping of the insulation.

3. To ensure a reliable termination, the correct connector for a given cable size must be selected.
Moreover, the recommended indent tool or hexagon tool and die must also be used. See the various
data tables in this catalogue for tooling recommendations.

4. Fit the connector over the stripped conductor and place the connector into the hand or hydraulic tool.
Apply the recommended pressure. With hand tools, the crimp is not complete until the jaws
meet or the ratchet releases. With hex dies in hydraulic tools, the faces of the die must meet.

5. The number of crimps per connector can vary. Some lugs have markings for crimps, if you require more
information please contact Utilux.

TERMINATION RECOMMENDATIONS
The palm contact areas of Utilux lugs are designed to give more than that the surface of lugs are used upon has
corresponding contact area. Excessive drilling out of palm holes must be avoided, to ensure that adequate palm
contact, heavy gauge washers are recommended. in relation to stalk lugs and consistent with the above, care must be
taken to adequately match the stalk diameter of the tunnel or mounting connector, to ensure maximum surface
contact area. Bolting torques are listed in the following table.

Bolt Size Material Tightening Torque


3/8” Aluminium 20 Newton Metres
1/2” Aluminium 40 Newton Metres
M10 Aluminium 20 Newton Metres 10
M6 Steel 16 Newton Metres
M8 Steel 16 Newton Metres
M10 Steel 20 Newton Metres
M12 Steel 40 Newton Metres
M16 Steel 80 Newton Metres
M20 Steel 100 Newton Metres

119
TECHNICAL DATA

FLEXIBLE CABLE CRIMPING


The crimping of connectors onto flexible conductors is problematic due to the large amount of air gaps between
conductor strands. This results in a large physical size for a relatively small conductor cross section. Thus the standard
size lug for a given area of flexible conductor is usually too small. If a larger size lug is used instead, the standard die
for that size lug will not achieve the desired compression.

Indent crimping is not recommended, as the indent may damage the very fine strands of a flexible conductor which
may in turn cause connector failure.

Adopting the Utilux “Half Hex” crimping method solves the problem.
This method employs a crimping shape in the form of one half of the standard hexagon shape. The dies used
comprise a normal hexagon crimp die, along with a special flat die to give the half hexagon shape. The hexagon die is
sufficiently large to close around the lug completely, giving adequate compression.

Normally the conductor’s area will be known or can be located on the chart below. However if not known, it has to be
established. To do this we require the amount of strands and individual strand diameter. Counting the amount of
strands is not as daunting a task as it appears. The lay of the conductor will generally be a series of bundled strands,
with each bundle having the same lay as a regular laid conductor, eg 7, 19, 37 strands etc. Having established the
amount of strands to a bundle, count the amount of bundles and multiply. For example for a 95mm2 the conductor
may be 259/0.7 with a nominal diameter of 13.8mm, from this the true area is 99.7mm2. The diameter is too large for a
95mm2 barrel but will fit a 120mm2 barrel. It can then be crimped using the half hex method.

Rule of thumb for matching conductor to lug, providing conductor diameter allows, is whatever the area of the
conductor, choose the next size larger lug.

CSA mm2 NO & DIA OF WIRES OD OF CONDUCTOR CALCULATED CSA mm2

16 128/0.4
540/0.2 5.8 15.8
25 209/0.4
770/0.2 7.5 24.2
35 285/0.4
1083/0.2 8.6 34.0
50 380/0.4
1558/0.2 10.5 49.0
70 203/0.67
2204/0.2 11.6 69.3
95 259/0.67
2983/0.2 14.8 93.7
120 336/0.67
3810/0.2 15.9 119.7
150 427/0.67
4773/0.2 18.6 150.0
185 528/0.67
5881/0.2 184.8
5920/0.21 18.8 205.1
240 672/0.67
7400/0.21 23.7 256.3
73630/0.2 239.7
300 8911/0.2 280.0
9102/0.21 26.6 315.3
400 11970/0.2 376.1
12672/0.21 30.8 438.9

120
TECHNICAL DATA

FLEXIBLE CONDUCTOR SIZE


UTILUX CRIMP LUG (mm2) UTILUX HALF HEX UTILUX HALF HEX RECOMMENDED
PART NUMBER RANGE SET PART NUMBER DIE SET CONSISTS OF UTILUX TOOLING
NOMINAL
MIN MAX
H1415A M6
H1415 M8 Half 38-98CU
H1416 M10 16 15 19.3 38-98HHEX17/1 plus
H1416A M11 38-FLAT17
H1416B M12
H1365 M6
Half 38-98CU
H1366 M8
25 23.5 30.5 38-122HHEX17/1 plus
H1368 M10
38-FLAT17
H1369 M12
H1419 M6 Half 38-130CU
H1420 M8 35 27.5 35 38-130HHEX17/1 plus
H1421 M10 38-FLAT17 #38A
H1422B M6 #38ROBO
H1422A M8 Half 38-153CU #41A
H1422 M10 50 47.5 58 38-153HHEX17/1 plus #42A
H1423 M12 38-FLAT17 #66H
H1423A M16 #98
H1424B M6 #98H
H1424C M8 #98ROBO
H1424 M10 HAlf 38-183CU
70 66.5 82 38-183HHEX14/1 plus
H1425 M12
H1440 M16 38-FLAT14
H1438 M20
H1381 M10
Half 38-220CU
H1382 M12
95 89.5 112.5 38-220HHEX14/1 plus
H1383 M16
38-FLAT14
H1382B M20
H1384A M10
Half 38-245CU
H1384 M12
120 113.5 141.5 38-245HHEX14/1 plus
H1385 M16
38-FLAT14
H1386 M20
H1387A M10
Half 40-260CU
H1387 M12
150 131 162.5 40-260HHEX25/1 plus
H1388 M16
40-FLAT25
H1389 M20
H1390 MB
H1390D M10 Half 40-310CU
H1390A M12 185 174.5 219.5 40-310HHEX25/1 plus
H1390B M16 40-FLAT25
H1390C M20 #40B
H1391 MB Half 40-340CU #40BH
H1391A M16 240 226.5 283.5 40-340HHEX25/1 plus
H1391B M20 40-FLAT25
H1448 MB Half 40-370CU
H1448A M16 300 266 330.5 40-370HHEX25/1 plus
H1448B M20 40-FLAT25
H1449 MB Half 40-410CU
H1449A M16 400 381.5 460 40-410HHEX25/1 plus
H1449B M20 40-FLAT25 10
Notes:
1.Refer to pages 2 & 3 for copper lug descriptive part numbers
2. To calculate cross sectional area of cable, use following formula;
Nxd x π
2
CSA =
4
3. Cable chart is for single core double insulated flexible cables 0.6/1kV V90.

121
TECHNICAL DATA

METRIC DESCRIPTION
For simplicity in identifying connectors in this catalogue, we have designated certain products with metric coding.
This coding can be used to identify a product if the Utilux catalogue number is unknown.

The following coding applies:


A = Aluminium K = Link
B = Bi-Metal S = Sector
C = Copper M = Palm Hole in mm
G = Lug MB = Blank Palm

AGS = Aluminium Lug Sector


AKS = Aluminium Link Sector
BGS = Bi-Metal Lug Sector
BKS = Bi-Metal Link Sector
AG = Aluminium Lug AK = Aluminium Link
BG= Bi-Metal Lug BK = Bi-Metal Link
BS = Bi-Metal Stalk CG= Copper Lug
CK = Copper Link

The cable area in sqmm and the palm hole is included to complete the description, eg:
(a) BKS70/50 is a Bi-Metal Link Sector, 70mm2 solid aluminium to 50mm2 stranded copper.
(b) AGS300/M16 is an Aluminium Lug Sector Cable 300mm2 solid 16mm palm hole.
(c) AKS240 is an Aluminium Link Sector Cable 240mm2 solid.

Note: This guide covers a wide, but not exhaustive, range of our products. If you have a special requirement
it may be available in our extensive non standard range or, through our Utilux Express service. Please
discuss with your Utilux distributor.

122
TECHNICAL DATA

ERGONOMIC DESIGN –
THE KEY TO SAFE, COMFORTABLE WORK PRACTICE
Poorly designed hand tools can often cause strain injury to the hands or lower arm and, at best, can make
repetitive tasks tiring and uncomfortable. The Utilux range of Ergonomic Design Hand Crimp Tools combines
high quality and durable design and manufacture with the best of current ergonomics science for optimal
operator safety and comfort. These tools, developed in co-operation with prominent ergonomists, offer
maximum performance and user-friendliness. Some important features are;

GOOD MECHANICAL FUNCTION


The lower the hand force required to operate a tool, the
lower is the risk of overloading and injury. Utilux Ergonomic
Design Tools are equipped with a unique mechanism which
reduces the need for muscle force by 45%.

OPTIMUM GRIP DIAMETER


The position at which the hand can transfer most force
The optimum grip diameter is the width of the handles measured at the
centre of the hand. Tools should be designed so that the maximum
with minimal stress varies from individual to individual
force needed is required at the optimum grip diameter. and is also significantly different between men and
women. Utilux Ergonomic Design Tools feature handle
designs that provide a comfortable optimum grip zone for
any operator.

TWO HAND GRIP FEATURE


Our Ergonomic Design Tools feature handles which allow
two-hand operation in the final, high force, crimping
phase. This dramatically increases crimping force while
The shape of the handles offers a comfortable
reducing the possibility of strain or injury.
one-hand grip even at maximum opening.
WEIGHT AND BALANCE
Low weight and good balance are an integral comfort and
safety feature of Utilux Ergonomic Design Tools. Handles
are precisely shaped to distribute the loading across the
palm and four fingers rather than concentrating it on only
a few fingers. This distributes surface pressure over the
largest possible area of the hand.

The unique mechanical advantage means that very small HANDLE MATERIAL
forces are required to crimp the connector and cable Material used for handle grips is carefully selected to
to fix them in the correct position.
exhibit the correct co-efficient of friction when in contact
with the skin. This reduces slippage and increases control.

THE HAND – A PRECISION TOOL


The human hand is a powerful, precision tool in its own
right. It is our most important means of contact with the
environment. But, like any precision instrument, it is
sensitive to abuse. The use of quality ergonomically
correct tools will help protect this most important part of
When the connector and cable are fixed, the final crimping the human body.
10
can be done with a comfortable two-hand grip.

123
SPARE PARTS LIST

#38 . . . . . . . . . . . . . . HAND OPERATED HYDRAULIC CRIMPING TOOL


#98 . . . . . . . . . . . . . . HAND OPERATED HYDRAULIC CRIMP TOOL
#41AH . . . . . . . . . . . HEAVY DUTY HYDRAULIC CRIMPING HEAD (C FRAME)
#98H . . . . . . . . . . . . HEAVY DUTY HYDRAULIC CRIMPING HEAD (C FRAME)
#40BH . . . . . . . . . . . . HYDRAULIC CRIMPING HEAD
#67H . . . . . . . . . . . . HEAVY DUTY HYDRAULIC CRIMPING HEAD (U FRAME)
#38 ROBO . . . . . . . . . ROBO BATTERY OPERATED HYDRAULIC CRIMPING TOOL
#UC6ROBO . . . . . . . HEAVY DUTY BATTERY OPERATED HYDRAULIC CRIMPING TOOL
#98ROBO . . . . . . . . . HEAVY DUTY BATTERY OPERATED HYDRAULIC CRIMPING TOOL
#REC 50U . . . . . . . . . BATTERY OPERATED CABLE CUTTER
#CCSP55 . . . . . . . . . HYDRAULIC CABLE CUTTER HEAD
#CCSP100 . . . . . . . . HYDRAULIC CABLE CUTTER HEAD
#CCS20A . . . . . . . . . . HAND OPERATED HYDRAULIC CABLE CUTTER
#CCS40A . . . . . . . . . HAND OPERATED HYDRAULIC CABLE CUTTER
#108 . . . . . . . . . . . . . RATCHET CABLE CUTTER

CATALOGUE INDEX INDEX


Product - #38A
SPARE PARTS LIST Description - Hand Operated Hydraulic Crimping Tool
Product - #40BH
SPARE PARTS LIST Description - Hydraulic Crimping Head
Product - #38 ROBO
SPARE PARTS LIST Description - Battery Operated Hydraulic Crimping Tool
Product - #108
SPARE PARTS LIST Description - Ratchet Cable Cutter

NO. DESCRIPTION CODE QTY


1 Hex. nut RCC-01 1
2 Lock washer 16-02 2
3 Stationary blade RCC-03 1
4 Moving Blade RCC-03 1
5 Pivot Pin RCC-04 1
6 Gear Shaft RCC-05 1
7 Stop knob RCC-06 1
8 Screw RCC-07 2
9 Hex. nut RCC-08 1
10 Pawl RCC-09 1
11 Small gear RCC-10 1
12 Large gear RCC-11 1
13 Housing RCC-12 1
14 Star washer RCC-13 1
15 Bolt RCC-14 3
16 Hand crank RCC-15 1
17 Gear pin RCC-16 1
18 Spring RCC-17 1
19 Pawl stopper RCC-18 1
20 Ratchet lever RCC-19 1
21 Ball RCC-20 1
22 Spring RCC-21 1
23 Handle spring RCC-22 1
24 Medium gear RCC-23 1
25 Dowel pin RCC-24 1
26 Stationary handle RCC-25 1
27 Moving handle RCC-26 1
28 Handle retainer RCC-27 1
29 M10 x 10 Hex screw RCC-28 1
Product - #98
SPARE PARTS LIST Description - Hand Operated Hydraulic Crimp Tool
Product - #41AH
SPARE PARTS LIST Description - Heavy Duty Hydraulic Crimping Head
(C Frame)
Product - #98H
SPARE PARTS LIST Description - Heavy Duty Hydraulic Crimping Head
(C Frame)
Product - #67H
SPARE PARTS LIST Description - Heavy Duty Hydraulic Crimping Head
(U Frame)
Product - #UC6ROBO
SPARE PARTS LIST Description - Heavy Duty Battery Operated Hydraulic
Crimping Tool
Product - #98ROBO
SPARE PARTS LIST Description - Heavy Duty Battery Operated Hydraulic
Crimping Tool
Product - #REC 50U
SPARE PARTS LIST Description - Battery Operated Cable Cutter
Product - #CCSP55
SPARE PARTS LIST Description - Hydraulic Cable Cutter Head
Product - #CCSP100
SPARE PARTS LIST Description - Hydraulic Cable Cutter Head
Product - #CCS20A
SPARE PARTS LIST Description - Hand Operated Hydraulic Cable Cutter
Product - #CCS40A
SPARE PARTS LIST Description - Hand Operated Hydraulic Cable Cutter